HVCA - DW144 - Spec For Sheet Metal Ductwork

Specification for
Heating and
Ventilating
Sheet
Licensed copy: arup31277, Arup, 24/02/2010, Uncontrolled Copy, ®HVCA Publications
Contractors’
Association
Metal
Ductwork
DW/144
DW/l44
Specification for
Sheet Metal Ductwork
Low, medium and high

pressure/velocity air systems
1998
Copyright © 1998 by the

Heating and Ventilating
Contractors’ Association
All rights reserved
ISBN 0-903783-27-4
Further copies of this publication are available from:
Publications Unit
Heating and Ventilating Contractors Association
Old Mansion House Eamont Bridge
Penrith Cumbria CA10 2BX
Tel: 01768 864771 Fax 01768 867138
e-mail: hvcapublications@hvwelfare.co.uk
THE INDUSTRY
STANDARD
Ken Parslow
Chairman
Executive Committee
Ductwork Group
1996-98
or more than a decade-and-a-half, the DW/142 Specification for Sheet Metal
F Ductwork published by the Heating and Ventilating Contractors’ Association

has gained national and international recognition as the industry standard
against which the quality of ductwork manufacture and installation can be judged.
In recent years, however, it has become increasingly evident to the members of
the HVCA Ductwork Group that the developments in technology and working
practices which have taken place since the drafting of DW/142 have rendered
obsolete significant parts of the document.
It was an acknowledgement of this state of affairs which led the Technical Sub-
Committee of the Ductwork Group, ably chaired by Edgar Poppleton, to undertake
the task of producing a radically revised specification which would promote best
practice and quality standards well into the next Millennium.
This new publication — designated DW/144 — represents the direct result of
that initiative.
The new specification recognises the computer age — with special reference to
CAD/CAM procedures and techniques — and the international performance stan-
dards established by the Committee for European Normalisation (CEN), as well as
the need to update and consolidate much of the information contained in the origi-
nal DW/142 publication and its Addendum A companion volume.
During the drafting process, the Technical Sub-Committee has consulted widely
with individuals and organisations throughout the building services and construc-
tion sectors in order to ensure that the new specification fully reflected the current
the “state-of-the-art” in terms both of technical expertise and industry best practice.
I firmly believe that this process has resulted in a publication which clearly
demonstrates the high level of professionalism which exists within the ductwork
community — and I take this opportunity of thanking all those who have con-
tributed to its production.
In particular, my thanks go to Edgar Poppleton and his colleagues on the
Technical Sub-Committee, to Keith Elphick for the provision of invaluable techni-
cal consultancy, and to Ductwork Group secretary Gareth Keller for overseeing the
project as a whole.
3
MAINTAINING QUALITY
ike most industries, the ductwork sector Class A, B and C air leakage characteristics,
L must be prepared continually to innovate in

order to survive and prosper.
A key element in that innovation process is the
•
mandatory testing Class C only;
updated appendices on galvanising
manufacture, stainless steel, pre-coated steel,
after
timely review and updating of quality standards to aluminium, Eurovent and galvanised material,
ensure that they continue to offer realistic bench- plus a bibliography;
marks to which all professional individuals and
organisations can perform.
• transport, handling, storage and interface with
DW/TM2 Guide to Good Practice — Internal
The development of this new Specification for Cleanliness of New Ductwork Installations;
Sheet Metal Ductwork — designated DW/144 — Edgar Poppleton • an overview of fire-rated ductwork;
has been carried out with that objective in mind. Chairman • a new appendix on inspection, servicing and
In the 16 years since the publication of its Technical cleaning access openings (the default inclusion
predecessor, DW/142 — and in the ten years since of Level 1 should be noted);
Sub-Committee
the supplementary volume Addendum A appeared
— many technical advances, changes in working
Ductwork Group • a new section on standard component drawings
— incorporating a framework of nomenclature,
practices and regulatory introductions and amend- and a description of drawing symbols, abbrevia-
ments have taken place. tions and rules — which is intended to reduce
The common performance standards for duct- ambiguity and promote common understanding;
work being developed by the Committee for
European Normalisation (CEN), for example, had
• a rewritten description of all forms of dampers,
for which I am indebted to Bill Clark and John
to be taken fully into account during the drafting Mawdsley of the HEVAC Association.
process. Similarly, notice had to be given to the I take this opportunity to acknowledge the per-
provisions of the Control of Substances Hazardous mission granted by the Sheet Metal and Air
to Health (COSHH) and Construction (Design and Conditioning Contractors’ National Association
Management) Regulations, neither of which had (SMACNA) of the USA for the use of its tie rod
been issued when DW/142 was published. specification (designer approval required).
It is not possible — nor, I think, desirable — to And I also include a plea on behalf of ductwork
include in this foreword an exhaustive catalogue of constructors to be allowed to make the final choice
the points of difference between this specification of components and techniques within the parame-
and its predecessor. These will clearly emerge ters set by the designer, and allowed within this
from a detailed reading of the text. specification to satisfy performance characteristics.
I should, however, like to take the opportunity It will, of course, be clear to anyone who has
to highlight a few topics which I believe to be of ever taken on such a task that the production of this
particular significance. They are: specification has involved a colossal input in terms
• the omission of high-pressure Class D (in order

to conform to European practice);
of industry consultation and from a wide variety of
individuals, a number of whom I should like to
• the highlighting of information to be provided

by the designer;
identify for special mention.
They are: former Technical Sub-Committee
• the end-sealing of ducts and explosion risks; members Keith Waldron and the late Keith Angood;
• the removal of standard sizes of rectangular

ducts;
current members Chris Collins, Stuart Howard,
Brian James and — last but by no means least —
• the omission of cleated joints; Jim Murray; technical consultant Keith Elphick; and
• the acceptance of proprietary flanges certificated

to DW/TM1 no longer illustrated in detail;
Ductwork Group secretary Gareth Keller.
Finally, may I remind readers of the crucial
• the consolidation into the document of coverage

of hangers and supports;
importance of ensuring that all ductwork is manu-
factured and installed in a manner which is safe,
• the addition of a note on linings, along with their

cleaning considerations;
efficient, effective and free of risk.
The publication of DW/144 is intended to assist
• the consolidated graphical representation of significantly in the achievement of this objective.
5
Acknowl e dge me nts
The HVCA wishes to record its sincere thanks to the following

members — past and present — of the Technical Sub-Committee
of the Ductwork Group, who contributed their time, knowledge
and experience to the production of this document
Edgar Poppleton (chairman)

Keith Angood
Chris Collins
Stuart Howard
Brian James
Jim Murray
Keith Waldron
Technical Consultant:
Keith Elphick
Ductwork Group Secretary:

Gareth Keller
6
Other Ductwork-Related Publications
DW/143 A Practical Guide to Ductwork Leakage Testing

DW/151 Specification for Plastic Ductwork
DW/171 Guide to Good Practice for Kitchen Ventilation Systems
DW/191 Guide to Good Practice: Glass Fibre Ductwork
DW/TM1 Acceptance Scheme for New Products: Rectangular Cross Joint Classification
DW/TM2 Guide to Good Practice: Internal Cleanliness of New Ductwork Installations
DW/TM3 Guide to Good Practice for the Design for the Installation of Fire and Smoke Dampers
TR/17 Guide to Good Practice: Cleanliness of Ventilation Systems
Copies of the above publications are available from:
Publications Unit
Heating and Ventilating Contractors Association
Old Mansion House Eamont Bridge
Penrith Cumbria CA10 2BX
Tel: 01768 864771 Fax 01768 867138
e-mail: hvcapublications@hvwelfare.co.uk
Previous Sheet Metal Ductwork Specifications

– Ductwork Specification for High-Velocity Air Systems (Circular) 1963
– Standard Range of Rectangular Ducting 1967
DW/131 Sheet Metal Ductwork Specification for High-Velocity Air
Systems (Rectangular) 1968
DW/121 Specification for Sheet Metal Ductwork (Low-Velocity
Low-Pressure Air Systems) (Rectangular and Circular) — Metric 1969
DW/122B Specification for Sheet Metal Ductwork (Low-Velocity
Low-Pressure Air Systems (Rectangular and Circular) — British 1969
DW/112 Standard Range of Rectangular Ducts and Fittings — Metric and
British Units 1970
DW/132 Specification for Sheet Metal Ductwork (High-Velocity
High-Pressure Air Systems) (Rectangular, Circular and Flat
Oval) — Metric 1970
DW/141 Specification for Sheet Metal Ductwork (Low and High-Velocity/
Pressure Air Systems) (Rectangular, Circular and Flat Oval)
— Metric 1977
DW/142 Specification for Sheet Metal Ductwork (Low, Medium and High
Pressure/Velocity Air Systems) 1982
DW/l42 Specification for Sheet Metal Ductwork Addendum A (Low,
Medium and High Pressure/Velocity Air Systems) 1988
7
Contents
Page 16.4 Fastenings 35

16.5 Stiffening 35
Notes 10 17. Construction (Straight Seamed) 35
18. Fittings 35
Part One - Technical Information to be
18.1 General Construction Requirements 35
provided by the designer
18.2 Standardisation of fittings 35
1. Introduction 11
2. Standards 11 Part Six - Hangers and Supports
3. Components 11 19. General 43
4. Particular Requirements 11
Part Seven - General
Part Two - Standards 20. Access/Inspection Openings 47
5. Application 13 21. Regulating Dampers 48

6. Ductwork Classification and Air Leakage 13 22. Fire Dampers 49
7. Materials 13 23. Smoke Dampers 50
8. Ductwork Construction and Joint Sealing 14 24. Combination Smoke and Fire Dampers 51
25. Flexible Ducts 51
Part Three - Rectangular Ducts
26. Flexible Joint/Connections 52
9. Rectangular Duct Sizes 15
27. Protective Finishes 53
10. Construction 15
28. Connections to Building Openings 53
10.1 General 15
29. Internal Duct Linings 54
10.2 Steel Thicknesses 15
30. Thermal Insulation 54
10.3 Longitudinal Seams 15
31. Kitchen Ventilation 54
10.4 Cross Joints 15
32. Fire Rated Ductwork 54
10.5 Stiffeners 15
33. Standard Component Drawings
10.6 Ductwork Galvanised After
and Abbreviations 54
Manufacture 16
10.7 Fastenings 16 Part Eight - Appendices
11. Fittings 16 Appendix A. Air Leakage from
11.1 Standardisation of Fittings 16 Ductwork 75
11.2 Stiffeners 16 Appendix B. Identification of
11.3 Splitters 16 Ductwork 80
11.4 Turning Vanes 16 Appendix C. Guidance Notes for the
11.5 Branches 16 Transport, Handling and
11.6 Change Shapes 16 Storage of Ductwork 82
11.7 Expansions and Contractions 17 Appendix D. Ductwork Systems and
11.8 Sealant 17 Fire Hazards 83
Appendix E. Hot Dip Galvanizing after
Part Four - Circular Ducts
Manufacture 85
12. Standard Sizes 27
Appendix F. Stainless Steel for Ductwork 86
13. Construction 27
Appendix G. Pre-Coated Steel 89
13.1 Longitudinal Seams 27
Appendix H. Aluminium Ductwork 90
13.2 Cross Joints 27
Appendix J. Eurovent 91
13.3 Fastenings 27
Appendix K. Summary of BS.EN10142:
14. Fittings 29
1991 Continuously Hot-Dip
14.1 Standardisation of Fittings 29
Zinc Coated Mild Steel Strip
14.2 Nominal Diameters 29
and Sheet for Cold Forming 92
14.3 Sheet Thickness 29
Appendix L. ‘Design Notes for Ductwork’
14.4 Sealing of Joints 29
(CIBSE Technical
Part Five - Flat Oval Ducts Memorandum No. 8) 93
15. Standard Sizes and Sheet Thicknesses 35 Appendix M. Guidance Notes For Inspection,
16. Construction (Spirally wound) 35 Servicing and Cleaning Access
16.1 General 35 Openings 94
16.2 Longitudinal Seams 35 Appendix N. Bibliography 95
16.3 Cross Joints 35 Appendix P. Conversion Tables 97
8
List of Tables 13-17 Socket and spigot cross joints 22
Table Page 18-24 Stiffeners 23
25-28 Tie rod assembly 24
Part Two - Standards
29 Hard and Easy bends 25
1. Ductwork Classification and Air
30 Turning Vanes 25
Leakage Limits 13
Part Four - Circular Ducts
31 Spiral and straight seams 29
2. Constructional Requirements
32-38 Cross joints spirally wound ducts 30-31
Low Pressure up to 500Pa 18
39-45 Cross joints straight seamed ducts 32-33
3. Constructional Requirements
Medium Pressure up to 1000Pa 19 Part Five - Flat Oval Ducts
4. Constructional Requirements 53-58 Cross joints spirally wound ducts 39-40
High Pressure up to 2000Pa 19 59-63 Cross joints straight seamed ducts 41-42
5. Fastening Centres 24
Part Six - Hangers and Supports
Part Four - Circular Ducts 64-75 Horizontal ducts

6. Standard Sizes 27 bearers and hangers 45-46
7. Spirally-Wound Ducts 28 76-77 Vertical ducts supports 46
8. Straight-Seamed Ducts 28
9. Permitted fastenings and maximum
78-79 Fire barrier/fire damper expansion 50
spacings 29
80 Flexible joint connections 52
10. Fittings Sheet Thicknesses 29
81-124 Standard component drawings -
Part Five - Flat Oval Ducts Rectangular 55-61
11. Standard sizes and sheet thicknesses 36 125-152 Standard component drawings -
12. Stiffening requirements Circular 62-67
low and medium pressures 37 153-167 Standard component drawings -
13. Stiffening requirements Flat Oval 68-70
high pressure 38 168-177 Plant/equipment/miscellaneous 71
14. Permitted fastenings and maximum
Part Eight - Appendices
spacings 40
178 Permitted leakage at various
Part Six - Hangers and Supports pressures 78
15. Supports for horizontal ducts - rectangular, 179 Example of duct identification symbol 81
flat oval and circular 44

16. Standard Abbreviations 72-73
Part Eight - Appendices
17. Air Leakage Rates 76
18. Recommended duct identification colours 80
19. Examples of further identification symbols 81
20. Ductwork galvanized after manufacture -
rectangular 85
21. Compositions of the commonly used
Stainless Steel grades 88
22. Rectangular aluminium ducts -
low pressure constructional requirements 90
23. Circular aluminium ducts -
low pressure constructional requirements 91
24. Zinc coating mass (weight) 93
25. Access requirements for inspection,
servicing and cleaning 94
List of Illustrations
Figs Pages

1-8 Longitudinal Seams 20
9 Illustrations of panel stiffening 20
10-12 Flanged cross joints 21
9
Notes
In this document:
(1) Even where a ductwork job specification calls for the system to be
wholly in accordance with DW/144, it will still be necessary for the
designer, in addition to providing drawings showing details and
dimensions of the ductwork, to identify specific requirements, par-
ticular to his or her design.
The technical information to be provided by the designer is there-
fore set out in detail on page 11.
(2) All dimensions quoted in this specification refer to the nominal
sizes, which are subject to the normal relevant commercial and
published tolerances.
(3) Manufacturing techniques are continually subject to change and

improvements and in respect of proprietary methods and devices
this specification does not preclude their use if they can be demon-
strated to the designer to be equally satisfactory. Where there is
divergence between the requirements of DW/144 and the
manufacturer’s recommendations for proprietary methods and
devices, the latter shall take precedence.
(4) The expressions ‘low-pressure,’ ‘medium-pressure’ and ‘high-
pressure’ relate to the pressure/velocity classes set out in Table 1.
(5) ‘Mean air velocity’ means the design volume flow rate related to
the cross-sectional area.
(6) Reference to the air distribution system pressure relate to the stat-
ic pressure of the relevant part of the ductwork system and not to
the fan static pressure.
(7) The symbol for litres is ‘L’: 1000 litres per second is equivalent to
1 cubic metre per second.
(8) The Pascal (Pa) is the internationally agreed unit of pressure. The
relationship of the Pascal to other units of pressure is: 500 pascals
= 500 Newtons per square metre = 5 millibars = approximately 2
inches water gauge.
(9)
Duct pressure classification
As the static pressure in a duct system progressively changes from the fan,
economic advantage can be obtained by changing the duct pressure
classification to match more closely the duct distribution static pressure.
For example, some large systems could well be classified for leakage
limits as follows:
Plant rooms and risers Class C

Main floor distribution Class B
Low-pressure outlets Class A
10
Part One – Technical information to be
provided by the designer to the ductwork contractor
1 INTRODUCTION 4.2 Protective finishes (Section 27)
The selection of constructional methods is the Details and specification of any protective
decision of the Manufacturer to conform with the finishes.
performance requirements of the specified 4.3 Fire rated and smoke extract ductwork
ductwork classification. Sections 2-4 below (Appendix D)
define the information that is to be provided by The extent and limits of protection for any fire
the Designer. resisting ductwork.
2 STANDARDS 4.4 Internal thermal/acoustic lining

(Section 29)
2.1 Pressure classification (Table 1) The extent of any ductwork requiring internal
2.2 Leakage classification (Table 1) acoustic/thermal lining is to be clearly identified.
2.3 Positive and Negative pressures (Table 1) A detailed specification of materials and method
2.4 Materials (Section 7) of application is required. The practical aspects
2.5 Any special system requirements of cleaning or maintenance must be addressed by
the designer before deciding to internally line
3 COMPONENTS
ductwork.
3.1 Inspection/servicing access openings
(Section 20 and Appendix M) 4.5 External thermal/acoustic insulation
Number and location of all panels and covers (Section 30)
for inspection and/or servicing access other than The extent and thickness of insulation to be
those covered in Section 20 and summarised as provided by others should be stated.
Level 1 requirements in table 25 of Appendix 4.6 Special supports (Section 19)
M. Number and location of test holes, Details of any spanning steel or special support
instrument connections and hinged doors as requirements not covered by Section 19
defined in Section 20. 4.7 Attachment to building structure (Section 28)
3.2 Cleaning access Specific requirements for the junction of
(Section 20.8 and Appendix M) ductwork and associated components to
Designers shall stipulate their requirements for openings should be detailed and specified and
periodic internal cleaning of ductwork and for the limits of responsibility defined.
the consequent need for adequate access for The provision of penetrations and associated
specialist cleaning equipment. framings are outside the scope of this
3.3 Regulating dampers (Section 21) specification.
Specification, location and mode of operation of 4.8 Air terminal units
all regulating dampers. Detail and specifications of all Air Terminal
3.4 Fire dampers (Section 22) Units. It is expected that all Air Terminal Units
Specification and location of all fire dampers to and their Plenums (See Figures 120 to 124) will
meet the requirements of the Authority directly be supported by the Ceiling Grids unless the
concerned with fire protection. designer indicates an independent method of
3.5 Smoke dampers (Section 23)/Combination support.
smoke and fire dampers (Section 24) 4.9 Ductwork layout drawings
Specification and location of all smoke dampers Details of any special requirements relating to
to meet the requirements of the Authority CAD, scales, etc. It is common practice and cost
directly concerned with fire protection. effective for ductwork manufacturers to utilise
3.6 Flexible ducts (Section 25) their approved ductwork layout drawings as a
Specification and location of any flexible basis of their manufacturing/installation
ductwork. information by adding the necessary details to
the same drawing. Scales of 1:50 or smaller may
3.7 Flexible joint connections (Section 26)
preclude this practice, therefore, larger scales
Specification and location of any flexible con-
might be more appropriate. The final choice of
nections eg. plant or building expansion joints.
manufacturing/installation scales shall be left to
4. PARTICULAR REQUIREMENTS the ductwork contractor.
4.1 Air leakage testing (Section 6 and Appendix A) 4.10 Other requirements
The extent of any air leakage testing. While it Details of any requirements for the ductwork
shall be mandatory for high-pressure ductwork not in accordance with the provisions of this
(as defined in this specification) to be tested for specification, including any modified con-
air leakage in accordance with the procedure set struction required to conform with any
out in DW/143, A practical guide to Ductwork requirements concerning external ductwork
Leakage Testing, no such testing of low- or (See 5.3) or to meet the regulations of a local
medium-pressure ductwork is required. authority or other controlling body.
11
4.11 Reference to the designer
In consideration of the foregoing, reference is also
made to the designer in the following clauses:-
Clause Page
5.3 13
7.4, 7.5, 7.6 14
10.5.2 16
11.1 16
14.1 29
16.3.1 35
19.1, 19.4 43
19.6, 19.7 44
20.1, 20.1.1.1, 20.6, 20.8 47
20.9 48
21.1, 21.3.1 48
21.3.4 49
22.3, 22.7 50
24.3 51
25.1 51
26.1 52
27, 27.3.4 53
29.1, 29.4, 30.2, 30.3, 33.2 54
Fig. 176 71
Appendix A 75-79
Appendix B 80, 81
Appendix C 82
Appendix D 83, 84
Appendix E 85
Appendix F 86-88
Appendix L 93
Appendix M 94
12
Part Two - Standards
5 APPLICATION 6.3 Leakage at various pressures; and other

5.1 This specification sets out minimum require- relationships
ments for the manufacture and installation of duct- Applying the limits specified in Table 1, Appendix
work for commercial and industrial air distribu- A (Table 17) sets out the permitted leakage at each
tion systems, made from any of the materials listed of a series of pressures up to a maximum for each
in Section 7 and being within the limits of size class. Included in that appendix is a graphical pre-
and/or metal thicknesses specified in the relevant sentation of the pressure/leakage relationship.
tables. Normal operating temperatures are DW/143 A practical guide to Ductwork Leakage
assumed within the pressure/velocity limits and Testing, also gives details of the basis for the
the limits of air leakage for the various pressure leakage limits specified in Table 1.
classes prescribed in Table 1.
5.2 This specification is not intended to apply to 6.4 Air leakage testing
ductwork handling air which is polluted or is other- Air leakage testing of low and medium pressure
wise exceptional in respect of temperature or ductwork is not mandatory under this specifica-
humidity (including saturated air); nor is it suitable tion.
for ductwork exposed to a hostile environment, Air leakage testing of high pressure ductwork is
e.g. contaminated air, off-shore oil rigs, etc. The mandatory under the specification and for details
design, construction, installation, supports and of testing procedure refer to DW/143 A practical
finishes in such cases should be given special con- guide to Ductwork Leakage Testing.
sideration in relation to the circumstances of each
case.
5.3 This specification is not suitable for ductwork
exposed to external atmosphere and the Designer
7 MATERIALS
will need to give specific details of any special
finishes/construction (See Section 27). 7.1 Application
This specification applies to ductwork constructed
from materials as defined below, or equal.
6 DUCTWORK CLASSIFICATION AND Minimum steel thickness is to be taken as a nom-
AIR LEAKAGE inal thickness within the tolerances to
BS.EN10143:1993. (See Appendix K)
6.1 Classification and air leakage limits
Ductwork classification and air leakage limits are 7.2 Zinc-coated steel
set out in Table 1. Ductwork will normally be constructed from
6.2 Compatibility with CEN hot-dip galvanized steel to BS.EN10142:1991,
The leakage factors used in Table 1 for Classes A, Grade DX51D+Z, coating type Z275.
B and C are the same as those for the classes
similarly designated in the CEN Document
Pr EN12237/Pr EN1507.
Ta b le 1 D u c t w o r k C l a s s i f i c a t i o n a n d Ai r L eak age L i mi ts
Static pressure limit Air leakage limits
Maximum air
Duct pressure class litres per second per square
velocity
Positive Negative metre of duct surface area
1 2 3 4 5
Pa Pa m/s
Low-pressure – Class A 500 500 10 0.027 x p0.65
Medium-pressure – Class B 1000 750 20 0.009 x p0.65
High-pressure – Class C 2000 750 40 0.003 x p0.65
Where p is the differential, pressure in pascals.
13
7.3 Mild steel 8.2.2 Liquid and mastic sealants
These are typically applied to a longitudinal
Where mild steel is specified, it shall be cold-
seam formed between two sheets of metal, a
reduced steel to BS.EN10130:1991, Grade FEP
socket and spigot, cleated or flanged cross joints.
01A.
Particular care is needed when sealing of “corner
7.4 Stainless steel pieces” on the proprietary ‘slide-on’ type flange
Where stainless steel is specified. it will be the and reference should be made to the manufac-
responsibility of the designer to indicate the type turer’s assembly and sealing instructions.
most suitable for the conditions to which the duct- 8.2.3 Gaskets
work will be exposed. In doing so, it is recom- These can be of various materials in the form of
mended that the factors set out in Appendix F a preformed roll, sheet or strip, applied between
should be taken into account. In this connection, opposing faces of flanged cross joints. In the
reference must be made to BS 1449: Part 2, which case of proprietary ‘slide-on’ type flanges, it is
includes stainless steel. advisable to use the gasket strip recommended
by the manufacturer.
7.5 Pre-coated steel
Pre-coated steel may be specified for aesthetic or Factory-fitted proprietary synthetic rubber ‘O’-
other reasons. The designer must then consider ring type gaskets are also acceptable for socket
the availability of suitable materials and the and spigot joints on circular duct systems.
restriction on fabrication methods. Guidance
notes are available in Appendix G. 8.2.4 Tapes
8.2.4.1 The application of tapes – Best
suited, but not limited, to cross joints on
7.6 Aluminium
circular or flat oval ductwork. Where chemi-
Where aluminium is specified, it will be the
cal reaction tape, heat shrinkable tape or other
responsibility of the designer to define the type
approved material is used on flat oval duct-
most suitable for the conditions to which the duct-
work care should be taken to maintain close
work will be exposed. Reference must be made to
contact between the material and the flat sides
BS.EN485, BS.EN515 and BS.EN573 for
of the duct until the joint is completed.
aluminium sheet and BS.EN755 Parts 3-6 for
aluminium section. (Constructional requirements 8.2.4.2 Chemical reaction tape – An
for ductwork made from aluminium sheet and impregnated woven fibre tape and a resin type
general notes on the material are set out in activator/adhesive. On application of the
Appendix H.) activator/adhesive the tape becomes pliable
and can then be applied to any surface shape.
The liquid reacts with the tape, causing the 2-
8 DUCTWORK CONSTRUCTION AND part system to ‘set’.
JOINT SEALING
8.2.4.3 Heat shrinkable band/tape – A ther-
8.1 Ductwork construction moplastic material, coated on the inside with
The selection of longitudinal, cross joint and stiff- hot metal adhesive. The band (or an appropri-
ener types within the criteria laid down in the ate length of tape) is cut from the roll and
tables should be the responsibility of the manu- wrapped around the joint. When heated the
facturer. tape shrinks tightly around the joint thus pro-
8.2 Joint sealing and sealants viding a seal.
8.2.1 General 8.2.4.4 Self adhesive tape – Manufactured
The integrity of the ductwork depends on the from various materials including cloth based,
successful application of the correct sealant, PVC and aluminium foil. Typically applied
gaskets or tape. The materials used should be externally to socket and spigot cross joints.
suitable for the purpose intended and satisfy the However, it is difficult to provide the dry, dust
specified pressure classification. and grease free surface that is required for a
Illustrations indicating sealant locations will be successful application and this method is
found in the following sections dealing with the therefore not recommended as a primary
construction of rectangular, circular and flat source of sealant.
oval duct sections. NB! Risk of explosions
IN ALL CASES, SEALANT MATERIALS Where ductwork is blanked off prior to leakage
MUST BE APPLIED STRICTLY IN testing or to prevent the ingress of contamination,
ACCORDANCE WITH THE MANU- care should be taken to ensure that all joint sealing
FACTURER’S INSTRUCTIONS AND solvent vapours are dispersed from the ductwork
COSHH ASSESSMENT. systems.
14
9 RECTANGULAR DUCT SIZES duct size longer side and maximum spacing, are
This specification covers duct sizes up to a maxi- given in Tables 2 to 4. Other limits on use are
mum longer side of 3,000 mm. Duct sizes with an given with the individual drawings.
aspect ratio greater than 4:1 are not recommend- Note: Proprietary products used in the construc-
ed. Although they offer no problems of construction of cross joints should be approved by an
tion, they increase frictional resistance and the independent test house following tests defined
possibility of noise.
in DW/TM1 “Acceptance scheme for new prod-

ucts – Rectangular cross joint classification.”
Figures Nos 10 and 13 to 17 illustrate non pro-
10 CONSTRUCTION
prietary joints that have an established rating.
10.1 General
The minimum constructional requirements for 10.4.2 Sealant in cross joints
rectangular ductwork depend upon the pressure Sealant shall be used between sheet and section
classification as set out in Tables 2 to 4. The duct- in all cross joint assemblies. (see section 8)
work construction and joint sealing standards are With socket and spigot joints made on site,
set out in section 8.
sealant shall be applied during or after assembly
10.2 Steel thicknesses of the joint. It is permissible to use chemical-
Minimum steel thicknesses related to duct longer reaction tape or heat-shrink strip as alternative
side to pressure classification are given in methods of sealing, provided that close contact
Tables 2 to 4. is maintained over the whole perimeter of the
10.3 Longitudinal Seams joint until the joint is completed.
Longitudinal seams are illustrated in Figs. 1 to 8. With all flanged joints, the sealant between
The limits of use, if any, are given with the indi- sheet and section should preferably be incorpo-
vidual illustrations. rated during construction at works, but site
10.3.1 Sealing of Longitudinal Seams applied sealant is acceptable. The joint between
Sealant will be applied using one of the follow- sections of ductwork is then made, using
ing methods: approved type of sealant or gasket. With
a) As an edge sealant on the external seam sur- proprietary flanging systems particular attention
face. should be paid to the sealing of corner pieces
b) As an edge sealant on the internal seam sur- and flanges, reference should be made to the
face. manufacturer’s assembly and sealing instruc-
c) Internal to the joint seam itself. tions.
The most appropriate method will be deter- 10.4.3 Adjustable/slip joints
mined by the manufacturer relative to their In order to accommodate manufacturing/build-
product and will be associated with either tradi- ing tolerances, site modifications etc, it is
tional fabrication/assembly methods, factory or accepted practice to use an adjustable joint as
site based, and/or proprietary methods. The ulti- illustrated in Fig. 14.
mate proof of a seal is that the ductwork system
meets the pressure classification specified. For
details of sealant see section 8. 10.5 Stiffeners
10.3.2 Welded seams 10.5.1 External stiffeners

A welded seam is acceptable without sealant, The sections (including proprietary flanges)
provided that the welding is continuous. suitable for use as single stiffeners have been
given a rating from S1 to S6 in terms of duct
10.4 Cross joints size longer side and maximum spacing. The rat-
10.4.1 Cross joint ratings ings are specified with the illustrations of the
For cross joints, a system of rating has been stiffeners, Figs. 18 to 23, and the limits of use
used to define the limits of use. The rating for are given in Tables 2 to 4. The stiffeners for
each cross joint is given with its drawing, and socket and spigot joints covered in Figs. 15, 16
the limits applying to that rating, in terms of and 17 are also applicable to stiffeners in general.
15
10.52 Internal stiffeners a minimum.
Tie bars connecting the flanges of cross joints Areas where the galvanizing has been damaged or
illustrated in Figs 11 and 12, are the only form destroyed by welding or brazing shall be suitably
of internal stiffening for rectangular ductwork prepared and painted internally and externally with
recognised by this specification and reference zinc-rich or aluminium paint as defined in Section
should be made to HVCA publication 27.3.2.
DW/TM1.
Alternative methods for the attachment of tie 11 FITTINGS
bars are shown in Figs. 25 to 28.
11.1 Standardisation of fittings
The use of tie bars or other forms of internal The terminology and descriptions of rectangular
stiffening or bracing shall be acceptable if duct fittings as set out in Section 33 are recom-
proved to the designer to be equally satisfactory. mended for adoption as standard practice to pro-
vide common terms of reference for designers,
SMACNA (Sheet Metal and Air Conditioning
quantity surveyors and ductwork contractors, and
Contractors’ National Association), which is the
American equivalent to the HVCA Ductwork of those using computers in ductwork design and
Group, have produced an Addendum No.1 fabrication.

(November 1997) to their publication “HVAC Bends are designated as ‘hard’ or ‘easy’, and these
Duct Construction Standards, Second Edition - terms as used herein have the following meanings:
1995”. The addendum contains the extensive
‘Hard’ signifies rotation in the plane of the
technical information and data on the subject of
longer side of the cross section.
mid panel tie rods and SMACNA have given
their kind permission for this specification to ‘Easy’ signifies rotation in the plane of the
make reference to this fact. Designers and man- shorter side of the cross section.
ufacturers who wish to incorporate this form of
An example illustrating these terms is given in
internal stiffening into a ductwork system
Fig. 29.
should contact SMACNA direct to obtain copies
of their publications (See Appendix N, 11.2 Stiffeners
Bibliography). The flat sides of fittings shall be stiffened in accor-
dance with the construction Tables 2 to 4. On the
10.6 Ductwork galvanized after manufacture
flat sides of bends, stiffeners shall be arranged in
Appendix E sets out the recommended sheet a radial pattern, with the spacing measured along
thicknesses and stiffening for ductwork galva- the centre of the bend.
nized after manufacture.
11.3 Splitters
10.7 Fastenings If the leading edge of the splitters exceeds 1250
10.7.1 Permitted types and maximum centres mm fit central tie bars at both ends to support the
Table 5 sets out the permitted fastenings and the splitters. Leading and trailing edges of splitters
maximum spacings for all ductwork classifica- must be edge folded and flattened and be parallel
tions. All duct penetrations shall be sealed. to the duct axis.
Splitters shall be attached to the duct by bolts or
10.7.2 Rivets mechanically-closed rivets at 100 mm maximum
Manufacturers’ recommendations as to use, spacing (or by such other fixing as can be shown
size and drill size are to be followed. Rivets re- to be equally satisfactory e.g proprietary sealed
sulting in an unsealed aperture shall not be used. splitter pins).
10.7.3 Set screws, nuts and lock bolts 11.4 Turning vanes
Materials shall be of mild steel, protected by Where specified, or shown on drawings, square
electro-galvanizing, sherardizing, zinc-plating, throat bends with either duct dimension greater
or other equal and approved corrosion resistant than 200 mm shall be fitted with turning vanes
finish. which are illustrated in Figures 30a and 30b.
Turning vanes at 60 mm maximum centres shall
10.7.4 Self tapping and piercing screws be fixed at both ends either to the duct or compat-
Providing an adequate seal can be achieved, and ible mounting tracks in accordance with manufac-
the protrusions into the ductwork are unlikely to turer’s instructions, the whole bank being fixed
cause injury, then self-tapping or piercing inside the duct with bolts or mechanically closed
screws may be used. rivets at 150 mm maximum spacing.
10.7.5 Welding of sheet The maximum length of turning vane between

duct walls or intermediate support shall be 615
The suitability of welding for sheet-to-sheet
mm for single skin vanes and 1250 mm for double
fastening will be governed by the sheet thick-
skin vanes.
ness, the size and shape of the duct or fitting and
the need to ensure airtighteness. Welded joints Typical examples of fitting turning vanes when
shall provide a smooth internal surface and shall the maximum permitted vane lengths are
be free from porosity. Distortion shall be kept to exceeded are shown in Fig. 30c.
16
11.5 Branches 11.7 Expansions and contractions
When fitting branch ducts to a main duct, care Where these are required, an expansion shall be
should be taken to ensure that the rigidity of the made upstream of a branch connection and a con-
duct panel is maintained in terms of the stiffening traction downstream of a branch connection. The
criteria. slope of either an expansion or a contraction
should not exceed 22½° on any side. Where this
11.6 Change shapes
angle is not practicable, the slope may be increas-
Where a change shape is necessary to accommo-
ed, providing that splitters are positioned to bisect
date the duct and the cross-sectional area is to be
the angle between any side and the centre line of
maintained, the slope shall not exceed 22½° on
the duct (See Figs 99 to 101).
any side (See Figs 99 to 103). Where a change in
shape includes a local reduction in duct cross-
11.8 Sealant
sectional area, the slope should not exceed 15° on
Sealant shall be used in all longitudinal seams and
any side and the reduction in area should not
cross joints of fittings. Sealant shall be to the
exceed 20 per cent.
options listed in Section 8.
17
Constructional Requirements – Rectangular Ducts
Table 2 LOW PRESSURE (limited to 500 Pa positive and 500 Pa negative)
Dimensions in mm
Maximum duct size

400 600 800 1000 1250 1600 2000 2500 3000
(longer slide)
Minimum sheet
0.6 0.8 1.0 1.2
thickness
Type Rating sheet Maximum spacing between joints and stiffeners
1 2 3 4 5 6 7 8 9 10 11 12
Socket & Spigot Joints
PS 3000
A1
SS 3000
PS 3000 2000 1600 1250
A2
SS 3000 3000 1600 1250
PS 3000 2000 1600 1250 1000 800

A3
SS 3000 3000 2000 1600 1250 800
PS 3000 1600 1250 625
J1/S1
SS 3000 3000 1250 625
PS 3000 2000 1600 1250 625
Flanged Joints & Stiffeners
J2/S2
SS 3000 3000 1600 1250 625
PS 3000 2000 1600 1250 1000 800
J3/S3
SS 3000 3000 2000 1600 1250 800
PS 3000 2000 1600 1250 1000 800 800
J4/S4
SS 3000 3000 2000 1600 1250 1000 800
PS 3000 2000 1600 1250 1000 800 800 800 625
J5/S5
SS 3000 3000 2000 1600 1250 1000 800 800 800
PS 3000 2000 1600 1250 1000 800 800 800 800
J6/S6
SS 3000 3000 2000 1600 1250 1000 800 800 800
Notes (applicable to Tables 2 to 4)

(1) The joints and stiffeners have been rated in terms of duct longer side and maximum spacing – see 10.4
for joints and 10.5 for stiffeners.
(2) In Col. 3:
‘PS’ = plain sheet
‘SS’ = stiffened sheet, by means of
(a) beading at 400 mm maximum centres: or (b) cross-breaking within the frame formed by joints and/or
stiffeners: or (c) pleating at 150 mm maximum centres.
(3) Stiffened panels may limit the choice of insulation materials.
(4) For ductwork galvanized after manufacture, see 10.6 and Appendix E.
(5) For aluminium ductwork, see Appendix H.
(6) For constructional constraints of stainless steel ductwork see Appendix F.
(7) Although not covered in this specification, due to their relatively infrequent use, cleated cross joints are
an accepted constructional practice and the HVCA Ductwork Group should be contacted if details of
their ratings and limitations are required.
(8) Intermediate stiffeners using rolled sheet angle profiles, illustrated in Figs. 19 to 23 of the appropriate
rating may also be utilised ensuring that rigid corners are achieved.
18
Table 3 MEDIUM PRESSURE (limited to 1000 Pa positive and 750 Pa negative
Dimensions in mm
Maximum duct size

400 600 800 1000 1250 1600 2000 2500 3000
(longer slide)
Minimum sheet
0.6 0.8 1.0 1.2
thickness
Type Rating sheet Maximum spacing between joints and stiffeners
1 2 3 4 5 6 7 8 9 10 11 12
Socket & Spigot Joints
PS 3000
A1
SS 3000
PS 3000
A2
SS 3000
PS 3000 1600 1250 1000 800

A3
SS 3000 3000 1600 1250 800
PS 3000 1250 625
J1/S1
SS 3000 1250 625
PS 3000 1250 1250 625

J2/S2
SS 3000 1600 1250 625
PS 3000 1600 1250 1000 800
J3/S3
SS 3000 3000 1600 1250 800
PS 3000 1600 1250 1000 800 800
J4/S4
SS 3000 3000 1600 1250 1000 800
PS 3000 1600 1250 1000 800 800 800 625
J5/S5
SS 3000 3000 1600 1250 1000 800 800 800
PS 3000 1600 1250 1000 800 800 800 800 625
J6/S6
SS 3000 3000 1600 1250 1000 800 800 800 625

Table 4 HIGH PRESSURE (limited to 2000 Pa positive and 750 Pa negative)
Dimensions in mm
Maximum duct size

(longer side) 400 600 800 1000 1250 1600 2000 2500
Minimum sheet
0.8 1.0 1.2
thickness
Type Rating Sheet Maximum space between joints and stiffeners
1 2 3 4 5 6 7 8 9 10 11
Spigot Joint s
A1 PS/SS 3000
Socket &
A2 PS/SS 3000
A3 PS/SS 3000
J1/S1 PS/SS 3000 625
J2/S2 PS/SS 3000 1250 800

J3/S3 PS/SS 3000 1250 1250 800
J4/S4 PS/SS 3000 1250 1250 1000 800
J5/S5 PS/SS 3000 1250 1250 1000 800 800 625
J6/S6 PS/SS 3000 1250 1250 1000 800 800 800 625
Notes on page 18 also apply to Tables 3 and 4
19
Longitudinal seams
For permitted fastenings (types and spacing), see Table 5
Fig. 1 Grooved seam Fig. 5 Returned standing seam (internal or

external)
Alternative sealant locations alternative
sealant
Fastening
locations
Fig. 2 Grooved corner seam Fig. 6 Capped standing seam (internal or

external)
Fastening
Alternative
sealant
locations Alternative sealant
locations
Fig. 3 Pittsburgh lock seam Fig. 7 Tray standing seam (internal or
external)
Fastening
Alternative
sealant
locations
Alternative
sealant locations
Fig. 4 Button punch snap lock seam Fig. 8 Lap seam
Alternative Fastening
sealant locations
Note. – This
seam is accept-
able for use
on low and
medium-pressure Alternative
ducts only
sealant locations
Fig. 9 Illustrations of panel stiffening

Cross breaking between
joints or stiffeners
Pleating (may also

be along the duct)
Beading (may also

be along the
duct)
Examples of Cross sections
20
Flanged cross joints
Minimum
Dimen- Rating Pressure Notes/corner treatments
Type classes
sions
Fig. 10 Rolled steel angle- Duct ends turned up 8 mm

flanged joint, with welded mm minimum
corners 25 x 3 J3
Fixing Low
Bolt 30 x 4 J4 Fixing bolts required at
Medium
40 x 4 J5 each corner and at 300 mm
High
Gasket or Sealant if 50 x 5 J6 centres.
sealant turn up not
used Angle flanged joint does NOT
Fixing Bolts
require DW/TM1 certification
25 x 3 6 mm
30 x 4 8 mm
40 x 4 8 mm A turn up as illustrated is NOT

Fastening Fastening 50 x 5 10 mm mandatory. If not used, the toe
of the angle is to be sealed.
Fig. 11 Examples of typical rollformed sheet metal profiles
Sealant, clamps/cleats and fixings omitted for clarity
Fig. 12 Examples of typical cross joint flanges formed from the duct wall
NOTE: The above illustrations are typical examples of cross joint profiles that are in common use for connecting
rectangular sheet metal ducts.
There are no set dimensions for these profiles shown in Figs. 11 and 12 provided they are certified under the HVCA
testing scheme DW/TM1 “Acceptance Scheme for new products – Rectangular cross joint classification” and are
appropriate to the duct application. The manufacturer’s technical data should be followed with respect to:
Connections to duct wall
Corner treatment
Addition of cleats
Application of sealants
Strength ratings
Application of tie bars
A list of manufacturers and profiles that are covered by current DW/TM1 certificate is available from the Ductwork
Group Secretary at HVCA.
21
Socket and spigot cross joints
Note – Particular care must be taken in the sealing of these joints. The ratings stated for cross joints
in Figs. 13 to 17 inclusive do not require DW/TM1 certification
For permitted fastenings (types and spacing), see Table 5
Angle Pressure
Type Rating Notes
size mm classes
Fig. 13 Plain
Alternative sealant locations Fastening

– Low
A1 Medium
High
Fig. 14 Adjustable
Low This joint can be used
A1 Medium on any ducts subject to
High the addition of an
Alternative sealant locations Fastening
adjacent stiffener with a
rating appropriate to the
duct size
Fig. 15 Angle reinforced (Ducts with

shorter side 400 mm and less)
25 x 3 A2 Low Locate stiffener back
from end of spigot
joint to allow access
for sealing joint
Corners can be mitred
A2 Low
30 x 4
Medium
Fig. 16 Back to back stiffeners (Ducts with Locate stiffener back

both sides greater than 400 mm) 25 x 3 A2 Low from end of spigot joint
to allow access for
sealing joint.
Stiffeners shown in Figs.

19 to 23 are permissible
if provided with rigid
corners.
Low
30 x 4 A3
Medium
Corners can be mitred
Fig. 17 Full girth welded stiffeners Locate stiffener back

(Ducts with both sides greater 25 x 3 A2 Low from end of spigot joint
than 400 mm) to allow access for
sealing joint.
Stiffeners shown in Figs.
19 to 23 are permissible
if provided with rigid
corners.
Low
30 x 4 A3 Corners can be
Medium
mitred
22
Single stiffeners
Dimensions and ratings
For permitted fastenings (types and spacings), see Table 5
Section H Thickness Rating

mm mm
Fig. 18 25 3 S2
30 4 S3
H
40 4 S4
50 5 S5
H 60 5 S6
Fig. 19
H 25 1.6 S1
2
H
30 1.6 S2
40 1.6 S3
50 2.0 S4
Fig. 20
20 1.6 S1
H 25 1.6 S2
35 1.6 S3
40 40 2.0 S4
Fig. 21 15 1.2 S1
20 1.2 S2
H
25 1.6 S3
40 1.6 S4
25 25 25 50 2.0 S5
Fig. 22
20 0.8 S1
H 30 1.0 S2
40 1.2 S3
Fig. 23
H 25 0.8 S1
Note – Other profiles may be used providing the duct deflection is limited to a maximum of 1/250 of the duct
side under operating pressure.
Intermediate Stiffeners
Fig. 24
For permitted fastenings (types and Full girth stiffener with
spacings) see Table 5 welded corners
Illustrations show rolled steel angle

stiffeners. Stiffeners shown in Figs. 19 to
23 are permitted. If used as full girth
stiffeners rigid corners are required.
Back to back stiffener with

bolted corners
Longest side stiffener

Ductwork with short side 400 mm and less
23
Tie rod assembly – alternative arrangement
Fig. 26 With tubing or

conduit and
Fig. 25 With internal and threaded inserts Fig. 27 With spacers
external nuts
Fig. 28 With shouldered rod
Table 5 Fastening Centres Dimensions in mm
Sheet to sheet Sheet to section (1)

Longitudinal Cross
Type Cross joints Stiffeners
seams joints
of
fastening Standing Socket Slide
Lap & Capped & RSA on
standing spigot flanges (4)
Mechanically
60 300 60 150 300 150 (5)
closed rivets
Self piercing screws 60 – 60 – 300 150
Lock bolts 60 300 – 150 300 300
Set screws & nuts – 300 – 150 300 300
Spot welds 30 150 – 75 300 150
Dimpling – 150 (2) – – 1.50 (3) –
(1) A minimum of 2 fixings per side, with a maximum distance from the corner to the first fixing of 50 mm
(2) Except when pierced dimpling is used, one of the other types of fastening must be used at each end in
addition to dimpling
(3) In addition to dimpling, one of the other types of fastening must be used at 450 mm centres, and in all
cases not less than 1 per side
(4) Where manufacturers have specific recommendations, then these shall take precedence over the centres
in the Table above
(5) Mechanically closed rivets are not recommended for fixing external stiffeners to ductwork exceeding
500pa negative.
24
Fig. 29 Bends - examples of ‘hard’
and ‘easy’
Hard
Easy
Fig. 30 Turning Vanes Example of bracing when vane length

Fig. 30c
exceeds max. permitted.
Alternatively use two banks of vanes
fixing the centre rails together at
150 mm centres.
Fig. 30a Single skin

vane
Max. vane length

Single skin – 615 mm
Double skin – 1250 mm
50 mm
90°
ELEVATION
Fig. 30b Double skin
vane
h
tc 25 x 50 x 1 mm
50 mm pi
m Channel or angle
m
25 mm 60 fixed to duct
wall both ends
90°
00
10
Fig. 30a and 30b
Maximum distance between M.10 clamping bolt
centres of turning vanes should at 1000 mm centres
not exceed 60 mm pitch.
SECTIONAL PLAN SHOWING TYPICAL EXAMPLE OF FIXING
25
26
Part Four – Circular Ducts
12 STANDARD SIZES ers and contractors in the meantime are invited to
evaluate them based on information currently
The duct sizes in Table 6 have been selected from
available.
the ISO and CEN Standard Ranges.
13.1 Longitudinal seams
Table 6 Circular Ducts – Standard 13.1.1 Spirally-wound ducts
Sizes The seam used in spirally-wound circular ducts,
provided it is tightly formed to produce a rigid
ISO standard sizes (nominal diameter)
duct, is accepted as airtight to the requirements
Duct Surface Duct Surface of all the pressure classifications covered in this
Area Area specification, without sealant in the seam.
mm m 2 /m mm m 2 /m
13.1.2 Straight-seamed ducts
63 0.198 * 400 1.257
The longitudinal seam for straight-seamed cir-
80 0.251 * 450 1.413 cular ducts shall be either the grooved seam
100 0.314 * 500 1.571 continued to the extreme end of the duct and
sealed, or a continuous butt lap weld or
125 0.393 * 560 1.760 spot/stitch weld and sealed lap joint (at 30 mm
* 150 0.470 * 630 1.979 centres) provided this gives a smooth internal
160 0.502 * 710 2.229 finish (see Fig. 31).
† 180 0.566 * 800 2.512 13.2 Cross joints

200 0.628 * 900 2.826 13.2.1 General
Cross joints for circular ducts, both spirally-
† 224 0.704 *1000 3.142
wound and straight-seamed, are illustrated in
250 0.785 *1120 3.517 Figs.32 to 45. They include several proprietary
† 280 0.880 *1250 3.927 types and the limits of use in terms of diameter
and pressure classes are noted against each.
* 300 0.943
13.2.2 Sealant
315 0.990 †1500 4.713
All circular cross joints shall be sealed. (see sec-
* 355 1.115 tion 8)
Note. The above sizes are subject to normal manufac- The use of chemical-reaction tape or heat-
turing tolerances. shrinkable band shall be regarded as an
Other sizes may be available from individual effective sealant in respect of the socket and
manufacturers including larger diameters up to spigot joints illustrated.
2000 mm.
13.2.3 Welded joints
*May be phased out of future CEN Standards. The limitations for welded joints are given in 13.3.5.
†Are neither ISO nor CEN Standards.
13.3 Fastenings
13.3.1 Permitted types and maximum centres
13 CONSTRUCTION Table 9 sets out the permitted fastenings and
maximum spacings for low-, medium- and high-
Spirally-wound ducts and straight seamed pressure ducts. All duct penetrations shall be sealed.
ducts
The minimum constructional requirements set out 13.3.2 Rivets
in Table 7 and 8 are common to the full range of Manufacturers’ recommendations as to use, size
pressures covered in this specification. and drill size are to be followed. Rivets
resulting in an unsealed aperature shall not be used.
The ductwork construction and joint sealing stan-
dards are set out in section 8. 13.3.3 Set screws, nuts and lock bolts
Materials shall be of mild steel, protected by
Spirally wound duct with thinner than traditional electro-galvanizing, sherardizing, zinc plating
wall thickness and with one or more corrugations or other equal and approved finish.
(ribs) formed between the lock seams are now
available. As design and installation experience 13.3.4 Self tapping and piercing screws
with these are gained and more functional perfor- Providing an adequate seal can be achieved, and
the protrusions into the ductwork are unlikely to
mance criteria are identified it is anticipated that
cause injury, then self-tapping or piercing
such forms may be added to later updates. Design-
screws may be used.
27
13.3.5 Welding of sheet internal surface and shall be free from porosity.
The suitability of continuous welding or spot Distortion shall be kept to a minimum.
welding for sheet to sheet fastening will be gov- Areas where the galvanizing has been damaged
erned by the sheet thickness, the size and shape or destroyed by welding or brazing shall be suit-
of the duct or fitting and the need to ensure air- ably prepared and painted internally and exter-
tightness. Welded joints shall provide a smooth nally with zinc-rich or aluminium paint.
Table 7 SPIRALLY-WOUND DUCTS (ALL PRESSURE CLASSIFICATIONS)

Maximum Minimum
(nominal) sheet Minimum stiffening requirements
diameter thickness
1 2 3
mm mm
80 0.4 None
160 0.5 None
315 0.6 None
800 0.8 None
None if helically beaded. If not helically beaded use

1000 1.0 Fig. 35 (angle reinforced) or Fig. 36, 37 or 38
(angle flanged) – all at 3000 mm maximum spacing.
1500 1.2 Figs. 36, 37 or 38 at 3000 mm maximum spacing.
Table 8 STRAIGHT-SEAMED DUCTS

Minimum sheet thickness
Maximum
(nominal) Low- and Minimum stiffening
High- requirements
diameter medium- pressure
pressure
1 2 3 4
mm mm mm
200 0.6 0.8 None
500 0.8 0.8 Swaged at spigot end as Figs. 39 and 40
800 0.8 1.0 Swaged at socket and spigot end as Figs. 39 and 4 0
1000 1.0 1.2 Figs. 42 to 45 at 1500 mm maximum spacing
1500 1.2 1.2 Figs. 42 to 45 at 1500 mm maximum spacing
28
14 FITTINGS Table 9 Permitted fastenings and
14.1 Standardisation of fittings maximum spacings –
The terminology and descriptions of circular duct circular ducts
fittings as set out in Section 33 are recommended
Sheet to section
for adoption as standard practice, to provide com- (jointing
mon terms of reference for designers, quantity Sheet to sheet flanges and
surveyors and ductwork contractors, and those Type of intermediate
using computers in ductwork design and fabrica- Fastening stiffeners)
tion.
Lap Cross Spirally Straight
The requirements for circular duct fittings apply Joints Joints wound seamed
throughout the pressure ranges covered in this
specification. 1 2 3* 4* 5*
14.2 Nominal diameters mm mm mm mm
The nominal diameter (see Table 6) is the size Mechanically
Closed Rivets 60 150 150 150
used for design and ordering. With socket and
spigot joints, care should be taken to ensure that Self piercing

the dimensions of the ducts and fittings are cor- screws 60 150 150 150
rectly related, so that the joint can be effectively
sealed. Set screws
and nuts – – 300 300
14.3 Sheet thickness
Sheet thickness for circular duct fittings (deter- 300 300
Lock Bolts 60 –
mined by the largest diameter) shall be not less
than those quoted in Table 10. Spot Welds 30 30 150 150
14.4 Sealing of joints
Sealant shall be used in all cross joints and fittings. * Minimum of three fixings
Such sealant shall be in accordance with the
requirements of Section 8.
Fig. 31
Spirally wound duct
Table 10 Circular duct fittings –

sheet thicknesses
Maximum Minimum sheet
nominal diameter thickness
1 2
mm mm
Straight-seamed 280 0.6

duct 500 0.7
630 0.8
1000 1.0
1500 1.2
Alternative
sealant
location
Lap seam (sealed)
Butt weld
29
Circular duct cross joints
Note – All duct penetrations shall be sealed
Limits of use
Spirally-wound ducts Angle Maximum Pressure
size diameter classes
mm mm
Fig. 32 Plain socket and spigot (duct to fitting)

Fastening
Low
– 1000 Medium
High
Alternative
sealant
locations
Fig. 33 Socket and spigot (duct to duct) with

connector Fastening
Low
– 1000 Medium
Alternative High
sealant
locations
Fig. 3 4 Socket and spigot with synthetic rubber

gasket
To be used strictly in
accordance with
manufacturers instructions
Fastenings
and size limitations.
Not suitable for helically beaded

Gasket spiral tube.
Fig. 35 Angle reinforced socket and

spigot
Fastening
*25 x 3 800 Low

*30 x 3 1000 Medium
Alternative
sealant 40 x 4 1500 High
locations
*Where angle rings specified
30
Limits of use
mm mm
Fig. 36 Example of typical roll formed

sheet metal profile
Fastenings and sealant

in accordance with To be used strictly in accordance with
manufacturer’s
instructions manufacturer’s recommendations
Fig. 37 Angle flanged (external)

Fixing Bolts
Fastening Fastening *25 x 3 800 Low

*30 x 3 1000 Medium
40 x 4 1500 High
Sealant Sealant
Sealant Turn up
or gasket minimum
of 8 mm *Where flanged joints are specified.
Note: A turn up as illustrated is not
mandatory. If not used the toe of
the angle is to be sealed.
Fig. 38 Angle flanged Alternative

(internal) sealant
Alternative sealant locations locations
*25 x 3 800 Low

Fastening *30 x 3 1500 Medium
Fastening
Sealant
40 x 4 1500 High
or gasket
*Where flanged joints

are specified
Note
Fixings for angle flanged joints Figs 37 & 38
Section size Bolt size
25 x 3 6 mm
@ 300 mm maximum centres
30 x 3 8 mm
40 x 4 8 mm minimum four per joint
31
Limits of use
Straight-seamed ducts Angle Maximum Pressure
mm mm
Fig. 39 Socket and spigot – plain Alternative
sealant
locations
800 Low
Fastening
Medium
high
Socket swage not required on

ducts 500 diameter and below
Fig. 40 Socket and spigot with connector

Alternative
sealant
locations
800 Low
Medium
High
Fastening Fastening

ducts 500 diameter and below
Fig. 41 Socket and spigot with synthetic rubber

gasket
To be used strictly in
Fastening accordance with
manufacturer’s instructions
and size limitations.
Gasket
Fig. 42 Socket and spigot – angle reinforced

sealant Fastening
locations
*25 x 3 800 Low

*30 x 3 1000 Medium
40 x 4 1500 High
Swage only
Alternative angle
required if
location, no swage
alternative angle
needed
location used
*Only where angle ring
specified
32
Limits of use
mm mm
Fig. 43 Roll formed flanged

in accordance with
To be used strictly in accordance with
manufacturer’s
instructions manufacturer’s recommendations
Fig. 44 Angle
flanged Fastening
Sealant if
turn up *25 x 3- 800 Low
not used 30 x 3 1000 Medium
40 x 4 1500 High
*Only where flanged joint specified

Fastening Sealant Turn up
or minimum Note: A turn up as illustrated is not
Gasket of 8 mm
mandatory. If not used the toe of the
angle is to be sealed.
Also acceptable with flange set
internally similar to Fig. 38
Fig. 45 Flat
ring flanged
25 x 3 800
Low
30 x 3 1000 Medium
Sealant
or 40 x 4 1500
Gasket
Turn up of
8 mm
Note
Fixings for angle flanged joints Figs 44 & 45
25 x 3 6 mm
8 mm @ 300 mm maximum centres
30 x 3
minimum four per joint
40 x 4 8 mm
33
34
Part Five – Flat Oval Ducts
15 STANDARD SIZES AND SHEET governed by the sheet thickness, the size and
THICKNESSES shape of the duct or fitting and the need to
15.1 Table 11 sets out the standard sizes of spirally- ensure air-tightness. Welded joints shall provide
wound oval ducts offered by the manufacturers of a smooth internal surface and shall be free
ducts of this section. from porosity. Distortion shall be kept to a
minimum.
16 CONSTRUCTION (SPIRALLY-WOUND
Areas where the galvanizing has been damaged
DUCTS)
or destroyed by welding or brazing shall be
16.1 General suitably prepared and painted internally and
‘Flat oval’ is the term used to describe a duct of externally with zinc-rich or aluminium paint.
cross-section with flat opposed sides and semi-
16.5 Stiffening
circular ends. The duct is formed from a spirally-
The larger sizes of flat oval duct are stiffened by
wound circular duct, using a special former.
swages, as indicated in Table 11. Additionally, tie
Apart from stiffening (see Tables 12 and 13), flat rods (see Figs. 25 to 28) are required, positioned
oval ducts have the same constructional require- as indicated in the respective tables and illustrations.
ments throughout the pressure ranges covered in
In special situations as an alternative to tie rods,
this specification.
stiffening in the form of external angles may be
The ductwork construction and joint sealing stan- used to meet the requirements of the corresponding
dards are set out in Section 8. rectangular duct sizes.
16.2 Longitudinal seams
Spirally-wound flat oval duct is accepted as airtight
to the requirements of this specification without
17 CONSTRUCTION (STRAIGHT-SEAMED)
sealant in the seams, provided the grooved seam is
tightly formed to produce a rigid duct. Flat oval ducts with opposed sides and
semi-circular ends may also be formed using
16.3 Cross joints plain sheet and straight seams. Ducts so formed
16.3.1 General should follow the metal thicknesses and stif-
Cross joints shall be as Figs. 53 to 58 inclusive fening requirements specified for the corres-
or such other joint as can be demonstrated to the ponding sizes of rectangular ducts, except that
designer to be equally satisfactory. stiffening is necessary on the flat sides only.
16.3.2 Sealant Seams and cross joints (see Figs 59 to 63) shall be
All flat oval cross joints shall be sealed. (See sealed to ensure the necessary degree of airtight-
Standards Section 8). ness throughout the pressure ranges covered in this
16.3.3 Welded joints specification.
The limitations for welded joints are given in
16.4.5.
16.4 Fastenings 18 FITTINGS
16.4.1 Permitted types and maximum centres
18.1 General constructional requirements
Table 14 sets out the permitted fastenings and
Sheet thicknesses for flat oval fittings (determined
maximum spacings for low-, medium- and high-
by the periphery of the larger end) shall be not less
pressure ducts. All duct penetrations shall be
than those given in Table 11 for the ducts them-
sealed.
selves.
16.4.2 Rivets
With socket and spigot joints, care should be taken
Manufacturers’ recommendations as to use, size
to ensure that the dimensions of ducts and fittings
and drill size are to be followed. Rivets resulting
are correctly related.
in an unsealed aperature shall not be used.
All the seams and joints integral to a fitting shall be
16.4.3 Set screws, nuts and lock bolts
sealed to the same standard as the duct. (See Sec-
Set screws and nuts shall be of mild steel,
tion 8).
protected by electro-galvanizing, sherardizing,
zinc plating or other equal and approved finish. 18.2 Standardisation of fittings
16.4.4 Self tapping and piercing screws The terminology and descriptions of flat oval duct
Providing an adequate seal can be achieved, and fittings as set out in Section 33 are recommended
the protrusions into the ductwork are unlikely to for adoption as standard practice, to provide com-
cause injury, then self-tapping or piercing mon terms of reference for designers, quantity sur-
screws may be used. veyors and ductwork contractors, and those using
computers in ductwork design and fabrication.
16.4.5 Welding of sheet
The suitability of continuous welding or spot The requirements for flat oval duct fittings apply
welding for sheet to sheet fastening will be throughout the pressure ranges covered in this
35
Table 11 Flat oval ducts – Standard sizes and sheet thicknesses
Nominal Surface Depth of duct (minor axis — ‘D’) — nominal

sheet area per
thickness metre
length length 75 100 125 150 200 250 300 350 400 450 500
1 2 3
mm sq. metres mm mm mm mm mm mm mm mm mm mm mm
0.718 320
0.798 360 350 330 320
0.878 400 390 370 360
0.8 0.958 440 430 410 400
1.037 480 470 450 440

(Width of duct (minor axis — ‘W’) — nominal — mm
1.117 520 505 490 480
1.197 545 530 520
1.277 555 525
1.436 635 605 580
1.596 715 690 660 630
1.756 800 770 740 710 685 655
1.915 880 845 825 790 765 735 705 680
2.075 960 930 900 875 845 815 785 755

Swaged
2.238 1040 1010 985 955 925 895 865 835
2.394 1120 1090 1065 1035 1005 975 945 915
2.553 1200 1170 1145 1115 1085 1055 1025 1000
1.0 2.873 1335 1305 1275 1245 1215 1190 1160
3.192 1465 1435 1405 1375 1350 1320
3.511 1625 1595 1570 1540 1510 1480
3.830 1785 1760 1730 1700 1670 1640
36
Table 12 – Flat oval ducts – low- and medium-pressure – stiffening requirements
Depth of duct (minor axis — ‘D’) – nominal

Tie rods
75 100 125 150 200 250 300 350 400 450 500
1 2
mm mm mm mm mm mm mm mm mm mm mm
320
360 350 330 320
Not required 400 390 370 360
440 430 410 400
480 470 450 440

Width of duct (major axis — ‘W’) — nominal — mm
520 505 490 480
545 530 520
555 525
635 605 580
Fig. 46 715 690 660 630

1000 mm centres
800 770 740 710 685 655
880 845 825 790 765 735 705 680
Fig. 47 960 930 900 875 845 815 785 755

750 mm centres
1040 1010 985 955 925 895 865 835
1120 1090 1065 1035 1005 975 945 915
Fig. 48 1200 1170 1145 1115 1085 1055 1025 1000

500 mm centres
1335 1305 1275 1245 1215 1190 1160
1465 1435 1405 1375 1350 1320
1625 1595 1570 1540 1510 1480
1785 1760 1730 1700 1670 1640
37
Table 13 – Flat oval ducts – high-pressure – stiffening requirements
Depth of duct (minor axis — ‘D’) – nominal

Tie rods
75 100 125 150 200 250 300 350 400 450 500
1 2
mm mm mm mm mm mm mm mm mm mm mm
320
360 350 330 320

400 390 370 360
440 430 410 400
Not required 480 470 450 440
520 505 490 480
545 530 520

Width of duct (major axis — ‘W’) — nominal — mm
Fig. 49 555 525

1000 mm centres
635 605 580
Fig. 50 715 690 660 630

750 mm centres
800 770 740 710 685 655
880 845 825 790 765 735 705 680
Fig. 51 960 930 900 875 845 815 785 755

500 mm centres
1040 1010 985 955 925 895 865 835
1120 1090 1065 1035 1005 975 945 915
1200 1170 1145 1115 1085 1055 1025 1000
Fig. 52 1335 1305 1275 1245 1215 1190 1160
1465 1435 1405 1375 1350 1320
1625 1595 1570 1540 1510 1480

Section A-A
1785 1760 1730 1700 1670 1640
A A
38
Flat oval duct cross joints
Note – All duct penetrations shall be sealed
Limits of use
Spirally-wound ducts Flange Maximum Pressure
size width classes
mm mm
Fig. 53 Plain socket and spigot (duct of fitting)

Fastening
Low
– 1785 Medium
High
Alternative
sealant
locations
Fig. 54 Socket and spigot (duct of duct) with

connector Fastening
Low
– 1785 Medium
Alternative
sealant
High
locations
Fig. 55 Alternative socket and spigot (duct to

duct) with connector and tie rod
Fastening
Low
Alternative — 1785 Medium
sealant High
loacations
The tie rod pattern to be in accordance with Tables 12 and 13.
Fig. 56 Example of typical roll formed

sheet metal profile

in accordance with To be used strictly in accordance with
manufacturer’s manufacturer’s recommendations
instructions
39
Limits of use
size width classes
mm mm
Fig. 57 Angle flanged (external)

Fixing bolts
Fastening Fastening *25 x 3 800 Low

*30 x 3 1040 Medium
40 x 4 1785 High
*Where flanged joints are specified.

Sealant Sealant
Sealant Turn up Angle flanged joint does not require
or gasket minimum
of 8 mm
DW/TM1 certification.
A turn up as illustrated is not
mandatory. If not used, the toe of the

angle is to be sealed.
Fig. 58 Angle flanged Alternative

(internal) sealant
Alternative sealant locations locations
*25 x 3 800 Low

Fastening Fastening *30 x 3 1040 Medium
Sealant
40 x 4 1785 High
or gasket
*Where flanged joints

are specified
Table 14 – Permitted fastenings and

Note
Fixings for angle flanged joints Figs. 57
maximum spacings – Flat oval ducts
& 58 Sheet to sheet Sheet to section
(jointing flanges
Type of Lap Cross and intermediate
Fastening joints joints Stiffeners
Section size Bolt size Flat Semi- Flat Semi-
sides circular sides circular
25 x 3 6 mm @ 300 mm maximum ends ends
30 x 3 8 mm centres. minimum 1 2 3 4* 5 6*
40 x 4 8 mm four per joint Mechanically mm mm mm mm mm
close rivets 60 60 150 150 150
Self piercing
screws 60 60 150 150 150
Set screws
and nuts – – – 150 300
Lock bolts 60 – – 150 300
Spot welds 30 30 30 75 75
*Minimum of two fixings.

Roll formed flanges shall be fitted strictly in accordance with
manufacturers instructions.
40
Limits of use
size width classes
mm mm
Fig. 59 Socket and spigot – plain Alternative

sealant
locations
800 Low
Medium
High
Fastening
Socket swage not reqauired on

ducts 500 wide and below
Fig. 60 Socket and spigot with connector

Alternative
sealant
locations
800 Low
Medium
High
Fastening Fastening

ducts 500 wide and below
Fig. 61 Socket and spigot – angle reinforced
sealant Fastening
locations
*25 x 3 800 Low
*30 x 3 1040 Medium
40 x 4 1785 High
Alternative angle
location (No swage
needed see 13.2)
*Only where angle ring
specified
Fig. 62 Angle
flanged Fastening
Sealant if
turn up
not used *25 x 3- 800 Low
30 x 3 1040 Medium
40 x 4 1785 High
Fastening Sealant Turn up
or minimum *Only where flanged joint specified.
Gasket of 8 mm Angle flanged joint does not
require DW/TM1 certification.
A turn up as illustrated is not
mandatory. If not used, the toe of
the angle is to be sealed.
Also acceptable with flange set
internally similar to fig. 58
41
Limits of use

size width classes
mm mm
Fig. 63 Flat
ring flanged
Sealant 25 x 3 800
or Low
Gasket 30 x 3 1040 Medium
Turn up of 40 x 4 1785
8 mm
Note
Fixings for angle flanged joints Figs. 62 & 63
25 x 3 6 mm
@ 300 mm maximum centres
30 x 3 8 mm
minimum four per joint
40 x 4 8 mm
42
Part Six – Hangers and Supports
19 GENERAL or studding or flat strap, pre-treated by, e.g. hot-

19.1 Principles adopted dip galvanizing, sherardizing, electro-deposited
Supports are an essential part of the ductwork zinc plating or by other accepted anti-corrosion
system, and their supply and installation are nor- treatment. Other materials, such as stranded
mally the responsibility of the ductwork con- wire, may also be acceptable.
tractor. The choice between the available methods Projection of a rod or studding hanger through
of fixing will depend on the type of building struc- the bottom bearer should, where practicable,
ture and on any limitations imposed by the struc- not exceed twice the thickness of the securing
tural design. Further, unless the designer has nut.
specified his requirements in detail, the load to be Provided the integrity of the ductwork is main-
carried shall be understood to be limited to the tained, hangers may be attached to the corners
ductwork and its associated thermal and/or of the flanges as an alternative to the use of a
acoustic insulation. bottom bearer.
It is not practicable to deal here with the full range
With proprietary devices manufacturers’
of supports available, which increasingly includes
recommendations for use should be followed.
proprietary types, so in this section various
methods of support are dealt with in principle 19.3.2 The duct bearing member
under the three elements of: The choice of the lower support will be dictated
(1) the attachment to the structure; by the actual duct section.
(2) the hanger itself; and 19.3.3.1 Rectangular ducts
(3) the duct bearing member
Table 15 gives minimum dimensions for the
with illustrations of those most commonly used. hangers and for angle, channel and profile sec-
Supports for ductwork external to the building have tions. The angle is shown in Fig. 73, the profile
been excluded, as these are individually designed channel sections in Figs. 74 and 75.
to suit the circumstances, and also may be required Typical arrangements of bottom bearer sup-
to meet local authority standards. For the same ports for plain, and insulated ducts are shown in
reasons, floor supports have not been dealt with. Figs. 68, 69 and 70.
With a proprietary device, it will, unless the
designer has specified his requirements in detail, 19.3.3.2 Circular ducts
be the responsibility of the ductwork installer to Table 15 gives minimum dimensions for the
ensure that it meets requirements, with a sufficient hanger and for the brackets – as illustrated in
margin of overload; and that it is installed in accor- Figs. 64 to 67.
dance with the manufacturer’s recommendations. 19.3.3.3 Flat oval ducts
The absence of any method or device from this Table 15 gives minimum dimensions for the
specification does not preclude its use if it can be hanger; and for the bearer, depending on
demonstrated that it is suitable for the duty whether the flat side of the duct is horizontal or
assigned to it, with a sufficient margin of safety vertical.
against overload; and this will be the responsi-
bility of the ductwork installer, unless the designer Typical arrangements for flat oval duct supports
has specified his requirements in detail. are shown in Figs. 68, 71 and 72.
19.2 Fixing to building structure 19.4 Vertical ducts

The fixing to the building structure should be of a The design of supports for vertical ducts is dictated
strength and durability compatible with those of by site conditions, and they are often located to
the ductwork support attached to it. A fixing to coincide with the individual floor slabs, but if the
concrete or brickwork must be made in such a way spacing exceeds 4 metres the designer must spec-
that it cannot loosen or pull out through normal ify his requirements.
stressing or through normal changes in the build-
Vertical ducts should be supported from the stif-
ing structure. fening angle or the angle frame, or by separate
19.3 Horizontal ductwork supporting angles fixed to the duct.
19.3.1 The hanger itself A typical method of supporting vertical rectangular
The hanger itself is usually mild steel plain rod ducts is shown in Fig. 76 and for circular ducts in
43
Fig. 77. The same methods are applicable to ver- The extent of any vapour sealing of ductwork
tical flat oval ducts. thermal insulation and the method to be used,
19.5 Heavy loadings must be clearly specified in advance by the
For ducts larger than those covered by Table 15, or designer.
where heavy equipment, mechanical services, 19.7 Heat transfer
ceilings or other additional load is to be applied to It is not normally necessary to make special
the ductwork, supports shall be designed to suit arrangements for the limitation of heat transfer
the applications. via the duct supports. However, there may be
19.6 Insulated ducts with vapour sealing special cases where the temperature difference
Where the temperature of the air within the justifies a heat barrier to conserve heat or to
duct is at any time low enough to promote con- prevent condensation and such requirements must
densation on the exterior surface of the duct and be specified by the designer.
cause moisture penetration through the thermal 19.8 Fire rated ductwork
insulation, vapour sealing may be called for, and DW/144 supports cannot be used on fire rated
in this case the most important requirement is to ductwork systems. See Appendix D and in
limit penetration of the seal. particular notes in D.2.1 Method 3 and D.2.3.
Table 15 Supports for horizontal ducts – rectangular, flat oval and circular
HANGERS BEARERS
Roll formed
channel
DUCT SIZES section SPACINGS
FLAT STRAPS STIRRUPS ANGLES
DROP profile
ROD W
DIAM H
RECT F’OVAL CIRC RECT F’OVAL CIRC R E C T F’OVAL CIRC RECT & F’OVAL RECT F’OVAL
CIRC
longer major Fig Fig Figs 64, Fig Fig Fig Fig Fig
diam 72
side axis 70 65, 67 69 71 66 68 68
1 2 3 4 5 6 7 8 9 10 11 12 13 14
mm mm mm mm mm mm mm mm mm mm mm mm mm mm
400 400 315 6 25 × 0.8 25 × 0.8 25 × 0.8 2.5 × 3 25 × 3 25 × 3 25 × 25 × 1.6 W H 3000 3000
plain plain plain 40 × 20 × 1.5
or or or
perf perf perf
600 605 457 8 30 x 3 25 x 3 25 x 3 30 x 3 30 x 3 30 x 3 25 x 25 x 3 40 x 20 x 1.5 3000 3000
1000 1040 813 8 N/A 30 x 3 30 x 3 N/A 30 x 3 30 x 3 30 x 30 x 3 40 x 20 x 1.5 3000 3000
1500 15
1510 1120 10 N/A N/A 40 x 5 N/A N/A 40 x 5 40 x 40 x 3 40 x 40 x 1.5 2500 3000
2000 1785 1525 10 N/A N/A 40 x 5 N/A N/A 40 x 5 50 x 50 x 5 40 x 40 x 2.5 2500 3000
1000 N/A 2000 12 N/A N/A 50 x 6 N/A N/A 50 x 6 60 x 60 x 6 N/A 2500 N/A
Notes to Table 15
(1) The dimensions included in Table 15 are to be regarded as minima.
(2) The maximum spacings set out in Table 15 are related solely to duct weight considerations. Closer spac-
ings may be required by reason of the limitations of the building structure or to achieve the necessary
duct rigidity.
(3) Rolled steel channels may be used as bearing members provided they meet the design characteristics of
the bearing members tabled above.
(4) As an alternative to drop rod or studding, wire rope may be utilised to suit individual manufacturer’s
fixing methods and loading limitations.
44
Arrangement of Bearers and Hangers
(to be read in conjunction with Table 15
which lists material sizes relative to duct sizes)
KEY Limits refer to actual duct sizes – insulation is additional

– Typical
– Attachment attachment
to structure to structure
Rectangular
– Flat Bar or flat oval
– Drop rod,
– Outline of
studding
Insulation (if
or
applicable)
wire rope
Fig. 68 Rolled or Profiled Bearer Limit: NONE
Alternative
Drop rod,
studding or
wire rope.
Fig. 64 Wrap-Round Hanger Limit: 315 DIA Fig. 69 Stirrup Limit: 600 wide
Alternative
Drop rod,
studding or
wire rope.
Limit: 315 DIA

Fig. 65 Flat Strap Hanger & Split Clips Fig. 70 Flat Strap Hanger Limit: 600 wide
Fig. 66 Stirrup Limit: 2000 DIA Fig. 71 Stirrup Limit: 1040 wide
Fig. 67 Flat Strap Hanger Limit: 2000 DIA Fig. 72 Flat Strap Hanger Limit: 1040 wide
45
SUPPORT BEARERS
Fig. 73
Rolled steel Fig. 75 Inverted profile
angle channel (alternatives)
Fig. 74
Profile
channel
(alternatives)
VERTICAL DUCTS Flat bar clips,

Stiffening frame Outline of insulation stiffening frame
or flanged joint (if applicable) or flanged joint
Support bearer
(see notes below)
Drop rod
or studding
Stiffening frame
or flanged joint
Fig. 76 Vertical rectangular ducts Fig. 77 Vertical circular ducts
The support bearer, which, depending on duct/structural opening size, could be either channel or angle
section, may be utilised in any of the following arrangements:-
a) Fixed directly to duct skin with sealed fixings (flat face only of either rectangular or flat
oval)
b) To support the underside of a flat bar clip in halves (circular or flat oval)
c) To support the underside of either the stiffening frame of the flanged joint of any duct
section
d) To support either a stiffening frame or a flanged joint below using drop rods/studding.
46
Part Seven – General
20 ACCESS/INSPECTION OPENINGS duct dimensions, openings for access shall

satisfy the maintenance needs of the designated
20.1 General
equipment with consideration being given, if
This section covers inspection/servicing access
more practicable, to the use of removable duct
only. Appendix M sets out guidance notes, in sum-
sections or flexible ducts/connections.
mary form, of the access considerations that
should be made by the designer in terms of 20.3 Inspection covers
inspection, servicing and cleaning access. It shall be standard practice to provide inspection
All openings shall be made safe and have sealed covers adjacent to regulating dampers where
panels/covers designed so that they can be speed- either the control linkage is mounted internally
ily removed and refixed. Multiple set screws are within the airstream or if a multi-bladed unit is an
not recommended, and self-piercing screws are integral part of the ductwork run. It is not neces-
not acceptable as a method of fixing. sary to provide inspection covers adjacent to
either single blade regulating dampers or flanged
The services co-ordinator should ensure that there
damper units.
is an area free of services and other obstructions to
enable a panel/cover to be removed. 20.4 Hand holes
Hand holes to permit proper jointing of duct
20.1.1 Function
sections shall be provided at the manufacturer’s
20.1.1.1 An access panel is to be provided
discretion, but should be kept to a minimum and
adjacent to items of in-line equipment that
made as small as practicable. The hand hole cover
require either regular servicing or intermittent
shall be sealed and securely fastened.
access. The opening will be sized to provide
hand and/or arm access only and the designer 20.5 Openings in insulated ducts
shall specify the size and location of panels It will be the responsibility of the insulation
where larger dimensions are required and in contractor to ‘dress’ their insulation to the edge of
these cases the panels should not exceed 450 the access opening without impeding the func-
× 450 mm. tionality of the panel, cover or door.
20.1.1.2 An inspection cover is to be provid- 20.6 Test holes for plant system commissioning
ed adjacent to items of in-line equipment that It shall be standard practice to provide test holes,
need visual inspection only of internal ele- normally 13 mm diameter and fitted with an effec-
ments from outside of the ductwork. The tive removable seal, at the following locations: at
inspection opening should have a minimum fans (in the straightest section of duct near to the
size of 100 mm sq/dia. fan outlet); at cooling coils and heating coils (both
20.2 Access panels before and after the coil). The actual location of
20.2.1 It shall be standard practice to provide the test holes shall be confirmed by the Designer
access panels for the inspection and servicing of and/or Commissioning Engineer either at the
plant and equipment as follows: drawing approval stage (to be works drilled) or
20.2.1.1 Fire/Smoke dampers during the commissioning activity (to be site
Panels to be located so as to give access both drilled). For practical access reasons the latter
to the blades and fusible links. On multiple method is usually preferred.
assembly units it may be necessary to provide 20.7 Instrument connections
more than one panel and this may be deter- Instrument connections shall be provided where
mined by both external access conditions and shown on the contract drawings, suitably drilled
the internal reach to the blades and the fusible or bossed and screwed as sizes specified.
links.
20.8 Cleaning/maintenance
20.2.1.2 Filters Designers shall take specialist advice and then
Panel to be located on the air entry side stipulate their requirements for the periodic
ie. upstream (Note: Dimensions of access may internal cleaning/maintenance of ductwork and of
need to be changed to suit filter elements of the consequent need for adequate access for spe-
the front withdrawal type.) cialist cleaning equipment including the size, type
20.2.1.3 Heating/cooling coils and in-duct and location/frequency of the actual access open-
fans/devices ings required.
Panel to be located on the air entry side
Appendix M sets out guidance notes for the
ie. upstream
consideration of cleaning access and also makes
20.2.2 It shall be standard practice to connect reference to the HVCA publication TR17 “Guide
safety restraints to access panels located in riser to Good Practice, Cleanliness of Ventilation Sys-
ducts. tems” which covers the subject in greater detail.
20.2.3 Subject to the restrictions imposed by
47
20.9 Openings required for other purposes Single-blade dampers (single-skin section) shall
It shall be the designers responsibility to specify have a maximum duct width of 300 mm and a
the location and size of any openings required maximum duct height of 300 mm for rectangu-
other than those covered in this section. In the lar ducts; and for circular ducts a maximum
case of hinged access doors it shall be the design- diameter of 315 mm.
er’s responsibility to indicate on the drawings the Single-blade dampers (double-skin section) are
location and size of any hinged access doors suitable for use in rectangular ducts, and shall
required, ensuring that there is an area free of ser- have a maximum duct width of 1250 mm and a
vices and other obstructions to enable the door to maximum height of 300 mm.
be satisfactorily opened. Unless otherwise speci-
fied by the designer, openings should not be larg- 21.2.2 Multi-blade dampers (single or
er than 1350 mm high by 500 mm wide. Doors double skin) parallel or opposed blade
could open against the air pressure. Both the Multi-blade dampers shall consist of a number
opening in the duct and the access door itself shall of pivoted blades contained within a casing. The
be adequately reinforced to prevent distortion. A blades shall be adjustable through a nominal 90°
suitable sealing gasket shall be provided, together angle simultaneously by interconnected linkage
with sufficient clamping type latches to ensure an or gears, connected to a quadrant or similar
airtight seal between the door and the duct. operating mechanism. Where automatic control
of the damper is required a spindle shall be
For safety reasons, the manufacturer shall incor-
porate means to prevent personnel being trapped extended to enable a powered actuator to be
inside the duct e.g. man access with operating mounted.
handles both inside and outside the duct. There is no restriction on the size of duct in
which multi-blade dampers or damper assem-
21 REGULATING DAMPERS blies may be used. Where dampers are required
21.1 General for blade lengths in excess of 1250 mm, the
Balancing dampers and control dampers are ele- blades should be suitably re-inforced or sup-
ments inserted into an air distribution system, or ported. No individual damper blade should
elements of an air distribution system. Balancing exceed 200 mm in width.
dampers permit modification of the air resistance 21.2.3 Iris dampers
of the system and consequently changing of the Iris dampers shall consist of a number of radial-
airflow rate. Control dampers control the airflow ly inter-connected blades which open or close
rate and in addition provide low leakage closure within a casing with duct connection spigots.
of the airflow. The blades shall be simultaneously adjusted by
The designer shall specify damper locations and a quadrant or similar operating mechanism.
select the damper type as defined in 21.2 appro- Iris dampers should be installed as specified by
priate to the airflow, pressure and acoustic the manufacturer’s operating and installation
characteristics. instructions, w h e r e t h e p r o d u c t i s u n i -
21.1.1 Balancing damper directional with regard to airflow.
To achieve the required distribution of air in the Iris dampers are available for circular ducts
ductwork system at inlets and/or outlets. For only, in diameters up to 800 mm (It should be
this purpose, the damper blades are set and noted that the damper casing is approximately
locked manually in any required position twice the diameter of the duct).
between fully open and fully closed.
21.2.4 Backdraft dampers
21.1.2 Control damper
Air pressure operated uni-directional rectangu-
To secure dynamic control of the air flow in the
lar (single or multi-blade) with adaptors if fitted
ductwork system. In this function, the damper
to circular or oval ducts.
will always be power – actuated and may
require to be modulated between fully open and 21.2.5 Hit and miss dampers
fully closed, and to be capable of taking up any Two parallel adjacent plates each with multiple
position between these extremes. In the fully open openings sliding against each other. The open-
position, the damper should have a minimum ings are designed to provide 50% air volume
pressure drop. In the fully closed position, it flow rates when they fully coincide. Used for
will not necessarily achieve a complete shut off. simple operations up to 400 mm longest side.
21.2 Types of airflow control damper 21.2.6 Slide and blast gate dampers
Air flow dampers of various types are available A damper used as a shut off facility, normally
for specific purposes as follows. for use in circular ductwork with an external
slide housing allowing a blade to be fully insert-
21.2.1 Single-blade dampers (Single or dou- ed to fully extended for maximum air flow.
ble skin)
Single-blade dampers shall consist of a single Generally available in cast/pressed formats up
pivoted blade contained within a casing or sec- to 355 mm diameter and normally used in
tion of ductwork. The blade shall be adjustable industrial exhaust applications.
through a nominal 90° angle by means of a
21.3 Construction
quadrant or similar operating mechanism.
Where automatic control of the damper is 21.3.1 Materials
required the spindle shall be extended to enable Dampers shall be constructed from steel, stain-
a powered actuator to be mounted. less steel, aluminium or synthetic materials.
48
All products shall be protected against corrosion 22 FIRE DAMPERS
as necessary and supplied in a fully finished
condition as specified by the designer. 22.1 General
Dampers are required in air distribution systems
21.3.2 Dampers used in low and medium
for fire containment. Generally they are called for
pressure systems
where ducts penetrate walls or floors which form
The following recommendations apply to
fire compartmentation. The damper assembly
dampers forming an integral part of ductwork
should have a fire resistance rating equal to that of
with pressure classification A and B air leakage
the fire barrier it penetrates and shall be fire test-
limits.
ed and rated to the time/temperature curve of
The dampers shall be constructed to prevent BS476 part 20 and 22.
distortion and jamming in operation. The blades
shall be sufficiently rigid to minimise move-
22.1 Types of fire dampers
ment when in the locked position.
Fire dampers of various types are available for
The blades shall be securely fixed to the operat-
specific purposes, as follows:
ing mechanism. Spindles shall be carried in
either non-ferrous, synthetic or roller bearings. 22.2.1 Folding curtain

All balancing dampers shall have a locking
device located on the outside of the case and Folding curtain fire dampers shall be con-
shall give clear indication of the actual blade structed of a series of interlocking blades which
position. All penetrations of the duct shall be fold to the top of the assembly permitting the
fitted with suitable seals where necessary. maximum free area in the airway. The blades
shall be held in the open position by means of a
21.3.3 Dampers used in high pressure thermal release mechanism rated at 72°C ± 4°C.
systems
Regulating dampers used in ductwork systems to The fire damper must be able to close against
pressure classification C shall meet the construc- static air conditions when mounted in either the
tion requirements specified in 21.3.1 and 21.3.2 vertical or horizontal planes.
with operating mechanisms out of the airstream.
In the event of a signal from a remote sensor the
21.3.4 Proprietary types of damper fire damper blades shall be released and close
The use of any specific type of proprietary the airway. A local excess temperature in the
damper shall be confirmed by the designer. In area of the fire damper shall, independent of any
all cases, proprietary dampers shall meet the remote sensors, automatically release the blades
relevant requirements of this specification. and close the airway by means of the thermal
21.3.5 Damper casings release mechanism, electric solenoid or electro-
Duct damper casings shall be constructed to magnet.
meet the minimum leakage limits specified for
22.2.2 Single blade
the ductwork system to which they are installed.
Single blade fire dampers shall consist of a
In order to apply the square metreage leakage single pivoted blade within a fire resistant case.
calculation as detailed in DW/143 A practical
guide to Ductwork Leakage Testing, the refer- The blade shall be released from its open posi-
ence casing area shall be taken as the perimeter tion by means of a thermal release mechanism
size of the damper multiplied by the equivalent rated at 72°C ± 4°C, electric solenoid, electro-
length of one metre eg. an 800 mm x 400 mm magnet(s) or other device.
duct damper shall have a surface area for casing
leakage performance calculated as follows; The blade shall close the airway by means of
[(2 x 0.8) + (2 x 0.4)] x 1 = 2.4m2 casing area. any one, or combination of, an eccentric pivot,
balance weight(s) and/or spring(s), the spring
Other performance and rating test methods for element being incorporated within the damper
dampers and valves are specified in ISO5129 or actuator mechanism.
and BS/EN1751, and are referenced below:
a) Leakage past a closed The fire damper shall be able to operate in either
or both the vertical and horizontal planes.
damper or valve BS/EN 1751
b) Flow rate/pressure
22.2.3 Multi-blade
requirement characteristics BS/EN 1751
c) Operational torque testing BS/EN 1751 Multi-blade fire dampers shall consist of a
d) Thermal transfer testing BS/EN 1751 number of linked blades contained within a fire
e) Regenerated sound power resistant case.
levels ISO 5129
The blades shall be released from their open
21.4 Installation position by means of either a thermal release
Dampers shall be installed in accordance with any mechanism rated at 72°C ± 4°C, or by the force
relevant ISO, EN or British Standard, local build- applied from electrical solenoid(s), electro-
ing regulations and national codes of practice as magnet(s), electrical/pneumatic actuator or
well as the manufacturer’s recommendations. other device.
49
ALTERNATIVE PROVISION FOR EXPANSION
Fig. 78 Fig. 79
This design was developed
in collaboration by HVCA This method is also normally used for a
and the HEVAC Association. multiple assembly of shutter-type dampers
Damper fixed on
centre of fire Expansion space
barrier or 50 mm filled with
Space for minimum on compressible
expansion access side of wall fire resistant
Close contact Damper packing
between damper Damper
and frame
Split frame assembled

around damper by
manufacturer/installer Angle frames
and built into fire secured after
barrier by builder. fire barrier
is built
The blades shall close the airway by means of a 22.5 Location

spring(s), the spring element being incorporated The effective formed barrier of the damper assem-
within the damper or actuator mechanism. bly shall be located within the structural opening.
The fire damper shall be able to operate in either Where this is not possible the section of the cas-
or both the vertical and horizontal planes. ing outside a fire barrier must have a fire resis-
tance not less than that of the fire barrier and be
22.2.4 Intumescent adequately supported/protected against the possi-
Intumescent fire dampers shall be constructed bility of displacement/damage by impact.
from strips of intumescent material formed into
a lattice or from honeycomb material covered 22.6 Provision for expansion
with intumescent paint. The damper shall fully Damper assemblies generally include built-in
seal when heat or flame is applied from either clearance frames to meet the requirement that the
side. Note: these devices are generally used in casing be free to expand in the event of fire. The
door/partition low velocity applications. integrity of the fire barrier is maintained either by
metal to metal contact or by fire resistant packing.
22.3 Materials and construction Acceptable arrangements are shown in Figs. 78
The damper shall be constructed from steel or and 79.
stainless steel or other approved material. Steel 22.7 Installation
products shall be protected against corrosion and Damper installation shall be in accordance with
supplied in a fully assembled condition as speci- the manufacturer’s recommendations and the
fied by the designer. impending HVCA Publication DW/TM3 – Guide
22.4 Air leakage to Good Practice, for the design for the installa-
Fire damper casings shall meet the equivalent tion of Fire and Smoke Dampers and any conflict
leakage performance standard specified for the between the two should be resolved and autho-
ductwork system to which they are installed. rised by the designer responsible for the fire
damper selection.
Classes A, B and C are used to signify the leakage
performance of the damper casing with the 23 SMOKE DAMPERS
respective testing method illustrated and specified 23.1 General
in BS/EN1751. Smoke dampers shall be constructed in such a
In order to apply the square metreage leakage cal- manner as to restrict the spread of smoke and
culation as detailed in the standard, the reference other products of combustion from one occupied
casing area shall be taken as the perimeter size of space to another. The blade(s) shall overlap each
the damper multiplied by an equivalent length of other and/or include edge seals. The blade(s) shall
one metre eg. an 800 mm x 400 mm duct damper be arranged to minimise the leakage of smoke. If
shall have a surface area for casing leakage per- degradable seals are fitted, care should be taken to
formance calculated as follows: [(2 x 0.8) + (2 x establish the temperature range of the material
0.4)] x 1 = 2.4m 2 casing area. used to ensure performance compatibility.
50
The smoke damper shall be able to operate in dampers shall consist of a single pivoted blade
either or both the vertical and horizontal planes contained within a fire resistant case.
and close against dynamic air conditions. The blade shall be released from its open posi-
23.2 Types of smoke damper tion by means of either a thermal release mech-
Smoke dampers of various types are available for anism rated at 72°C ± 4°C, or in addition oper-
specific purposes, as follows: ated by the force applied from electrical sole-
23.2.1 Single blade noid(s), electro-magnet(s), electrical/pneumatic
Single blade dampers shall consist of a blade of actuator or other device.
smoke tight material held in either the open or The combination smoke and fire damper shall
closed position by a mechanical linkage releas- be able to operate in either or both the vertical
ing to close or open and seal against the damper and horizontal planes and close against dynamic
case. The blade shall be mechanically connected air conditions.
to the actuator (electric or pneumatic) and shall 24.2.2 Multi-blade
be triggered by interfacing with a smoke Multi-blade combination smoke and fire
detector or fire control panel. dampers shall consist of a series of blades
23.2.2 Multi blade mechanically linked and connected to a damper

Multi blade dampers shall consist of blades of actuator with manual, electric or pneumatic
smoke tight material including the blade to opening and spring loaded closure contained
blade seals, where fitted. The blades shall be within a fire resistant case.
mechanically linked to an actuator (electrical or The blades shall be released from their open
pneumatic) to hold the blades in either the open position by means of either a thermal release
or closed position. The actuator shall interface mechanism rated at 72°C ± 4°C, or in addition
with a smoke detector or fire control panel and operated by the force applied from electrical
shall be so designed as to hold the blades close solenoid(s), electro-magnet(s), electrical/ pneu-
against the smoke seals, where fitted. matic actuator or other device.
23.3 Materials and construction The combination smoke and fire damper shall
The damper shall be constructed from steel, stain- be able to operate in either or both the vertical
less steel, other material or composite material and horizontal planes and close against
with blades fitted to reduce the leakage of smoke dynamic air conditions.
and hot gases when the blades are in the closed
position. Steel products shall be protected against 24.3 Materials and construction
corrosion and assembled in a fully finished condi- The combination smoke and fire damper case
tion as specified by the designer, in some circum- shall be constructed from steel, stainless steel,
stances controls may be supplied separately. other material or composite material with com-
pressible side seals fitted between the blade ends
23.4 Air leakage and the casing to reduce the leakage of hot gases
Smoke damper casings shall be as Clause 22.4 when the blades are in the closed position.
23.5 Installation Steel products shall be protected against corrosion
Damper installation shall be as Clauses 22.6 and and supplied in a fully finished condition as
22.7. specified by the designer.
24 COMBINATION SMOKE AND FIRE 24.4 Air leakage
DAMPERS Damper casings shall be as Clause 22.4.
24.1 General
24.5 Installation
Combination smoke and fire dampers are required
Damper installation shall be as Clauses 22.6 and
in air distribution systems to prevent the spread of
22.7.
smoke and hot gases from the fire zone and to
maintain the integrity of a fire rated structure for a
period compatible with that of the separating 25 FLEXIBLE DUCTS
structure. They shall be tested and rated to BS476 25.1 General
Part 20 and 22. Reference maybe made to BS5588 Flexible duct connections shall be used in the fol-
Part 4 for specific smoke rating requirements. lowing applications:-
The closure of the fire damper under action of the • Terminal units
thermal release element shall override all other • Fan coil units
subsequent signals. • Constant Volume/Variable Air Volume units
24.2 Types of combination smoke and fire
• Grilles and Diffusers
damper • Plenum boxes
Combination smoke and fire dampers of various • Distribution ducts between the above items.
types are available for specific purposes, as They are available in a range of materials includ-
follows: ing metal, P.V.C, fabric and with or without ther-
24.2.1 Single blade mal insulation.
Single blade combination smoke and fire The desi gner/ cont ract or shal l consi der t he
51
Flexible joint connections
Fig. 80 Rectangular, circular, flat oval alternative flanged, roll formed flange and spigot
connections
Effective length of the unsupported Effective length of the unsupported
material shall be material shall be
50 mm minimum – 250 mm maximum 50 mm minimum – 250 mm maximum
1. 5.
Flexible
material Metal
2. 6.
3. 7.
4. 8.
Note The ends of the flexible material must be lapped then stitched, glued or stapled using manufacturers
recommended glue and industrial staples to form an airtight joint.
following when selecting a particular type of 25.2.2 Flexible ducts – Fabric

flexible duct including: Flexible ducts made from materials including
• Temperature range P.V.C/Polyester laminate, Aluminium/Polyester
• Fire rating laminate encapsulating high tensile steel wire
• Resistance to air flow helix are a very flexible form of construction.
• Airtightness characteristics The length of flexible duct used should there-
• Length restrictions if applicable fore be kept to a minimum, consistent with the
• Support requirements particular application.
• Flexibility Flexible ducts shall be fastened at each end
• Insulation values using a propriety band. Care should be taken not
• System pressure. to damage the flexible duct and to ensure that
the required airtightness of the system is
Flexible ducts are also available in twin wall for- maintained.
mat where the inner liner is perforated to provide
acoustic properties or plain for thermal insulation. 25.3 Supports
Flexible ducts have a higher resistance factor than
conventional ductwork and should be supported
25.2 Flexible ducts – Metal in such a way that excessive sagging and conse-
2 5 . 2 . 1 Flexible ducts made of coated steel, quently kinking of the duct is avoided.
stainless steel or aluminium are normally heli-
25.4 Test Holes
cally wound with a lock seam to form a corru- It is not practicable to make test holes or take test
gated duct capable of being bent without readings in metal or fabric flexible ducts. Where
deforming the circular section. Bending is done readings are required, the test holes should be
by closing the corrugations in the throat and made in rigid ductwork.
slightly opening the corrugations at the back of
26 FLEXIBLE JOINT CONNECTIONS
the bend. Some re-adjustment is possible but
small radius bends cannot be straightened with- 26.1 General properties
out leaving some distortion of the corrugations. The material used for flexible joints must meet the
Repeated bending is not recommended. designers requirement for temperature, air pres-
sure, fire resistance, vibration, noise breakout
The ducts shall be mechanically fastened at when incorporated into a joint/connection and
each end and particular care shall be taken to shall comply with the standard of airtightness
ensure that the required airtightness of the specified for the ductwork system of which it
system is maintained. forms part (See Fig. 80 for typical connection
Fastenings should be as for rigid circular ducts details).
Section 13.3 and Table 9. Sealing should be as 26.2 Location
Section 8. Flexible joints are typically used at building
52
expansion joints and fan inlet/outlets. Any others 27.2 Metal spraying
required should be indicated on the design draw- Zinc or aluminium spraying shall be to BS EN
ings. Care should be taken to maintain alignment 22063 (1994), Part 1.
across joints/connections. 27.3 Paints
Joints/connections shall not be installed taught, 2 7 . 3 . 1 Surface preparation and paint
but under a reasonable amount of compression. application
26.3 Length Surface preparation of the metal and paint
Flexible joints shall be kept as short as practicable application shall be in accordance with the paint
above a minimum effective length of 50 mm. In no manufacturer’s recommendations.
case shall a flexible joint exceed 250 mm in length. 27.3.2 Making good welding damage
26.4 Connections to rectangular ducts Galvanizing or other metallic zinc finish
With flanged rectangular connections, the flexible damaged by welding shall be suitably cleaned
material shall be held in place with flat bar strips and painted with one coat of zinc-rich or
of not less than 2 mm thick attached to the flanges aluminium paint.
using suitable fixings. Where a proprietary brand
27.3.3 Ducts made from pre-galvanized sheet
of lightweight material is used with sheet metal

or coil
fitted to either side consideration should be given
Ducts and profile sections made from pre-
to the size of connection it is used on and how it
galvanized sheet or coil will have no need for
is fitted. The more heavy weight type of flexible
paint or further protection where located inside
material may also be obtained formed into a chan-
a building. This also applies to exposed cut
nel section with corners fitted and stitched to give
edges in accordance with criteria laid down by
a neat airtight joint. For spigot connections the
British Steel PLC. See Appendix N Bibliogra-
flexible material shall be held in place with flat
bar strips of not less than 2 mm thick. phy.
26.5 Connections to circular ducts 27.3.4 Ducts made from other types of mild
With flanged circular connections the flexible steel sheet
material shall be held in place with alternative flat Where circumstances require ducts to be made
bar rings, flat bar clip rings or proprietary clip from mild steel sheet or coil other than the
bands with screw or toggle fittings. Where a pro- foregoing, protective requirements shall be
prietary brand of light weight flexible with metal specified by the designer.
to either side is used, careful consideration must 27.3.5 Untreated steelwork profiles and sheet
be given to sealing when fitting to spirally-wound Any plain mill finish unprotected mild steel
ducts. such as rolled steel sections and/or sheet used
26.6 Connections to oval ducts for flanging, stiffeners, supports and duct walls
Special consideration should be given to the con- must be treated.
struction but the type of joint applies as for Treatment would be an appropriate primer such
circular ducts except proprietary clip band with as zinc rich, zinc chromate, red oxide or alu-
screw or toggle fastening is not suitable on oval minium paint.
ducts.
28 CONNECTIONS TO BUILDING
OPENINGS
27 PROTECTIVE FINISHES 28.1 Forming and finishing building openings are
not the responsibility of the ductwork contractor
Unless otherwise stated all ductwork will be
and the notes that follow are for guidance pur-
manufactured in pre-galvanised sheet steel,
poses only.
aluminium or stainless steel as specified, with
prime coating where applicable (see 27.3.5). Any 2 8 . 1 . 1 Openings in brick, block or concrete
additions to this would normally be the responsi- walls shall have inset frames to provide a suit-
bility of others. Any special coating/paint finishes able means of fixing grilles, louvres, masking
to be provided by the ductwork contractor must be flanges or the flanged ends of ductwork.
advised by the designer. The inset frames shall be constructed to main-
27.1 Galvanizing after manufacture tain the structural integrity of the wall and
Galvanizing after manufacture is not recom- where applicable cavities shall be suitably lined.
mended for general use, as distortion of the duct or 28.1.2 Openings in dry lining partitions shall
fitting is probable, thus making if difficult to have inset frames as in 28.1.1.
achieve an airtight joint. Galvanizing after manu- 28.1.3 Openings in cladding walls and roofs
facture is, however, an acceptable protective finish shall have flanged sleeves/frames to provide a
for circular pressed fittings and external ductwork suitable means of fixing as in 28.1.1.
exposed to atmosphere.
28.1.4 Horizontal and vertical openings that are
Where galvanizing after manufacture is specified, exposed to outside atmosphere shall be provided
it shall be to BS 729, see Appendix E. No paint with a suitable weathering finish at the external
protection is required. face especially if profiled cladding is involved.
53
2 8 . 1 . 5 Timber framed openings are not per- 30 THERMAL INSULATION
mitted in fire compartment walls.
30.1 The provision and application of thermal
28.2 Ductwork connections to building openings insulation to ductwork is not normally the respon-
shall have a flange of suitable profile to permit sibility of the ductwork contractor.
practical fixing to the opening frame. In selecting
the profile, consideration shall be given to Table 2 3 0 . 2 Where ductwork is required to be pre-
in this specification relating to duct size and insulated, the specification should be agreed with
rating. Gasket strip or sealer shall be applied the designer.
between the flange and building opening frame.
30.3 Where the temperature of the air within the
duct is at any time low enough to promote con-
29 INTERNAL DUCT LININGS
densation on the exterior surface of the duct and
29.1 General cause moisture penetration through the thermal
Where an acoustic or thermal lining to ductwork insulation, vapour sealing may be called for, and
is specified it should preferably be fitted at works. in this case the most important requirement is to
Before duct manufacture it should be clarified that limit penetration of the seal.
specified external duct dimensions allow for the
lining thickness. Any form of lining should have The extent of any vapour sealing of ductwork
fire characteristics having minimum Class O rat- thermal insullation and the support method to be
ing and must be specified by the Designer for used must be clearly specified in advance by the
material type, thickness, and application method. designer.
29.2 Lining Application Considerations 3 0 . 4 For detailed information on the thermal

Prior to the application of any lining the internal insulation of ductwork, reference should be made
duct surface must be thoroughly cleaned to to BS 5422:1990 which covers the specification
provide a dust free dry surface which may addi- for thermal insulation materials on pipes, duct-
tionally be degreased. work and equipment (in the temperature range
Securing the lining to the internal duct surface can –40°C to +700°C) and BS 5970:1992 which is a
be achieved in several ways including applied Code of practice for thermal insulation of
adhesive, self adhesive and physical methods such pipework and equipment (in the temperature
as fasteners in conjunction with surface washers at range –100°C to +870°C).
a specified square pitch.
Adjacent sections of lining should abut with mini-
mal gap and integral or separate surface finish lap 31 KITCHEN VENTILATION
to such joints and or gap filling proprietary 31.1 For detailed information reference should be
products being applied. This procedure is to obvi- made to HVCA Publication, Guide to good
ate any particle migration. Practice for Kitchen Ventilation Systems
DW/171.
During application and any curing, consideration
should be given to ambient temperature and
humidity requirements.
32 FIRE RATED DUCTWORK
In all circumstances linings should be fitted to 3 2 . 1 For information see Appendix D of this
material manufacturer’s recommended methods. specification.
29.3 Circular ducts
Lining circular ducts is impractical and is not rec-
ommended. 33 STANDARD COMPONENT DRAWINGS
AND ABBREVIATIONS
29.4 Cleaning and maintenance
Designers should be aware of the possible porous/ 3 3 . 1 The illustrations in this section not only
fibrous surface nature of linings as they may pre- highlight, where applicable, geometric limitations
sent practical/hazardous problems in cleaning and for the design and manufacture of ductwork com-
maintenance. Reference in this respect should be ponents but also recommend standard drawing
made to the following HVCA Publications representation, terminology and abbreviations for
both ductwork components and some of the more
i) DW/TM2 Guide to Good Practice, Internal
commonly used ancillary/plant items.
Cleanliness of New Ductwork Installations.
ii) TR17 Guide to Good Practice, Cleanliness 33.2 Designers and surveyors should note that
of Ventilation Systems. bills of quantities should provide a full description
54
STANDARD COMPONENT DRAWINGS — RECTANGULAR
FIG DRAWING DETAILS
Straight Duct with slip joints for ducts up to

81 400 mm longest size
Straight Duct with stiffened slip joints

N.B. Depending upon duct size additional stiffeners
82 may be required
Straight Duct with integral or slide-on flanges

83
N.B. Additional stiffeners may be required
Straight Duct with RSA flanges

84
N.B. Additional stiffeners may be required
W Mitred Throat Bend

85
For ducts up to 400 mm wide
Short Radius Bend

W
86 Applies to any angle and for ducts up to 400 mm
wide
Minimum throat radius = 100 mm
Medium Radius Bend (as illustrated)

Applies to any angle
W
87 Long Radius Bend

Similar but radius = W
Applies to any angle
Throat radius = W/2
Short Radius Bend with splitters
Splitter Position
C
‘W’ - mm Splitters
B
A B C
A
400–800 1 W/3 – –
88
801–1600 2 W/4 W/2 –
W 1601–2000 3 W/8 W/3 W/2
Minimum throat radius = 100 mm Splitters not required in bend angles less than 45°
55
FIG DRAWING DETAILS
89 Square Bend with turning vanes

90 Radius Tee with internal splitters
91 Radiussed Twin Bend
92
Swept Branch
93 Square Tee with Turning Vanes
94 Breeches Piece
56
FIG DRAWING DETAILS
95 ‘Y’ Piece
96 15° MAX. Angled Offset
30° MAX.
97
Mitred Offset
98
Radiussed Offset
Minimum throat radius = 100 mm
22.5° MAX.
Concentric Taper
22.5° max in either plane
99 Splitters are required for angles greater than 22.5°
and should bisect the angle between any side and
duct centreline
Eccentric Taper
22.5° MAX.
22.5° max in either plane
100 Splitters are required for angles greater than 22.5°
22.5° MAX. duct centreline
Offset Taper
101 22.5° MAX. Splitters are required for angles greater than 22.5°
duct centreline
57
FIG DRAWING DETAILS
22.5° MAX
102 Rectangular – Round Transformation

22.5° MAX
103
Rectangular – Flat Oval Transformation
104
Square Branch
105 Angled Branch
Branch duct Dimensions

width (W) (A)
mm mm
106 Up to 200 75
W
Shoe Branch
„ 300 100
A „ 400 125
„ 600 150
45° MAX
Over 600 200

45° MAX width (W) (A)
A
mm mm
107 Bell Mouth Branch Up to 200 75
W
„ 300 100
„ 400 125
„ 600 150
Over 600 200

width (W) (A)
mm mm
108 A Bell Mouth Up to 200 75
„ 300 100
45° MAX „ 400 125
„ 600 150
W Over 600 200
58
FIG DRAWING DETAILS
TJ SMF
Telescopic Joint
109
Illustrated with SMF – self metal flange
110 SBD Single Bladed Damper

111 NRD
Non-Return Damper
Multi-Leaf Damper
Can be spiggoted or flanged,
opposed or parallel blade
Alternative controls are:-
112 HD Hand
MD Motorised
PD Pneumatic
113 BG Blast Gate Damper
Fire/Smoke Dampers
2hr 2hr. Rating
With installation frame

114
4hr 4hr. Rating
SD Smoke damper
59
FIG DRAWING DETAILS
Access Openings
AP AP Access Panel – Removable
AD AD Access Door – Hinged
115
IC IC
Inspection Cover
IC IC
116 Flexible Connection
117
Drop Cheeked Radiussed Twin Bend
118 Drop Cheek Bend
119
Air Flow Symbol
60
FIG DRAWING DETAILS
Air Terminal Plenums
120 Plenum with side connection

121 Plenum with top connection
122
Cover plate with connection
123 Special plenum with connection
Telescopic connection
124
in direction of air flow
THE ABOVE DETAILS ARE TYPICAL

PLENUMS
61
STANDARD COMPONENT DRAWINGS — CIRCULAR
FIG DRAWING DETAILS
Straight Duct
125 With male and female connectors
(MALE) (FEMALE)
126 Straight Duct

With flange joint and slip joint
127 Pressed Bend

Applies to any angle, eg. 30°, 45°, 60°
Medium radius bend as illustrated.
D
Long radius similar but throat radius = D
THROAT RADIUS = D/2 AS STANDARD
Segmented Bend
90° four section minimum as illustrated
128
Other Angles
D 60° = 3 sections
45° = 3 sections
30° = 2 sections
THROAT RADIUS = D/2 AS STANDARD
62
FIG DRAWING DETAILS
Segmented Twin Bend

129 Radius = D/2 max
R
May also be fabricated from pressed bends
130 Pressed Equal Tee
131 Pressed Twin Bend
15° MAX.
Taper
132 Concentric 15° in either plane as illustrated.
Eccentric 30° included angle.
133 45° MAX. Short Taper
63
FIG DRAWING DETAILS
30° max Offset

134
Square Branch
135 Off rectangular

dia (D) (A)
Shoe Branch mm mm
D
136 Off rectangular Up to 200 75

„ 300 100
A „ 400 125
45° „ 600 150
Over 600 200

dia (D) (A)
Conical Branch mm mm
137 Up to 200 75
D
Also acceptable with

„ 300 100
full conical surface „ 400 125
A
END VIEW „ 600 150
45°
Over 600 200
138 Angle Branch
139
Square Branch
140 Shoe Branch
64
FIG DRAWING DETAILS
141 Pressed Branch


dia (D) (A)
mm mm
142 Bell Mouth Branch Up to 200 75
„ 300 100
„ 400 125
A 600 150
END VIEW „
45° Over 600 200
143 Mitred Branch
144 Blank End
Multi-Leaf Damper
Can be spiggoted or flanged,
opposed or parallel blade.
Alternative controls are:-

145
HD Hand
MD Motorised
PD Pneumatic
65
FIG DRAWING DETAILS
146 Single Bladed Damper
SBD
Non-Return Damper
147 NRD
Vertical application only
148 Iris Damper
ID
Fire/Smoke Dampers
2hr 2hr Rating
149 With installation frame
4hr 4hr Rating
SD Smoke damper
150
Breeches Piece
30° TO 90°
66
FIG DRAWING DETAILS
Access Openings
AP Access panel – removable
AD Access door – hinged
151
IC
Inspection cover
IC
2D
1.5D
D/2
152 Discharge Cowl

D/2
Inner cone optional

D/3
67
STANDARD COMPONENT DRAWINGS — FLAT OVAL
FIG DRAWING DETAILS
General Note:
In describing flat oval ductwork, the major axis is
referred to as the width (W) & the minor axis is
referred to as the depth (D).
For tie rod requirements see Tables 12 and 13
153 Straight Duct with connectors

W
WITH TIE ROD
154 Straight Duct with flange joint and slipjoint

W
W Segmented bend (easy)

D
155 Other angles

60° = 3 sections
45° = 3 sections
30° = 2 sections
THROAT RADIUS = D/2
AS STANDARD
Segmented bend (hard)

156 Other angles
60° = 3 sections
W D
45° = 3 sections
30° = 2 sections
THROAT RADIUS = W/2
30° MAX
W
Mitred Bend – Easy

157
D
68
FIG DRAWING DETAILS
30° MAX
158 Mitred Bend – Hard

W
D
22.5° MAX
159
W
Taper – Concentric
D
22.5° MAX
W
160
Taper – Eccentric
D
22.5° MAX
DIA
Flat Oval – Circular

Transformation piece
W
161
Can be concentric, eccentric or offset
D
22.5° MAX
22.5° MAX
Flat Oval – Rectangular

162 Transformation piece
W
Can be concentric, eccentric or offset
22.5° MAX
69
FIG DRAWING DETAILS
30° MAX
163
D
Offset - Easy
W
30° MAX
164
W
Offset - Hard
Branches
165 Note: For rectangular or circular branches off the flat
or circular part of the flat oval, see the appropriate
rectangular or circular Fig Nos pages 58, 64 and 65
166 Square Branch as illustrated

NB! Shoe branch similar to Fig. 136 also acceptable
W
BRANCH
DUCT
WIDTH Branch duct Dimensions
width (A)
45°
A mm mm
167 Conical Branch Up to 200 75
„ 300 100
W
„ 400 125
„ 600 150
Over 600 200
D
70
STANDARD COMPONENT DRAWINGS — PLANT/EQUIPMENT/MISCELLANEOUS
FIG DRAWING DETAILS
168 Rectangular Attenuator
169 Circular Attenuator

170 Bend Attenuator
171 Heating Coil
172 Cooling Coil
173 Electric Heating Coil
174 Humidifier
175 Axial Fan
Non-standard Ductwork
Cross hatching (of any separate type) indicates by reference to
176
a key, any non DW/144 ductwork system. eg. internally lined,
fire rated, stainless steel, aluminium, pre-coated or other.
177 Flexible Ductwork
71
TABLE 16 — STANDARD ABBREVIATIONS
ABBREVIATION FULL
AD Access Door
AFF Axial Flow Fan
AHU Air Handling Unit
ALI Aluminium
AP Access Panel
ATT Attenuator
ATU Air Terminal Unit
BE Blank End
BG Blast Gate Damper
CC Cooling Coil
CF Centrifugal Fan
CTA Cross Talk Attenuator
CVU Constant Volume Unit
DP Drain Point
EHC Electric Heating Coil
FAI Fresh Air Inlet
FA From Above
FB From Below
Flex/C Flexible Connection
Flex/D Flexible Duct
FC False Ceiling
FCU Fan Coil Unit
FD Fire Damper
FFL Finished Floor Level
FJ Flanged Joint
FOB Flat on Bottom
FOT Flat on Top
FRP Fire Retardent Polypropylene
GAM Galvanised after Manufacture
GRP Glass Reinforced Plastic
GSS Galvanised Sheet Steel
HC Heating Coil
HD Hand controlled Damper
HH Hand Hole
HL High Level
IC Inspection Cover
ID Iris Damper
IU Induction Unit
LL Low Level
MD Motor controlled Damper
MS Mild Steel
NRD Non Return Damper
72
TABLE 16 — STANDARD ABBREVIATIONS — CONTINUED
ABBREVIATION FULL
NTS Not to Scale

OBD Opposed Blade Damper
OE Open End
PBD Parallel Blade Damper
PD Pneumatic controlled Damper
PP Polypropylene
PRD Pressure Relief Damper
PVC Polyvinyl Chloride

RFC Rolled Form Channel
RSC Rolled Steel Channel
RU Roof Unit
SBD Single Blade Damper
SD Smoke Damper
SJ Slip Joint
ST/ST Stainless Steel
SSL Structural Slab Level
TA To Above
TB To Below
TD Top Down (In Direction of Flow)
TJ Telescopic Joint
TP Test Point
TV Turning Vane
TU Top Up (In Direction of Flow)
UOS Unless Otherwise Stated
UPVC Unplasticised Polyvinyl Chloride
US Underside
VAV Variable Air Volume
40 SMF Self Metal Flange (With Size)
50 RSA Rolled Steel Angle (With Size)
73
74
Part Eight—A ppendices
AP P E NDI X A — A I R LE A K A G E F ROM DUCT WORK

To be read in conjunction with DW/143 A practical guide to Ductwork Leakage Testing
CAUTION
As highlighted in both this document and DW/143, not enough emphasis can be placed on the fact that, except for high
pressure class C, the much tighter ductwork constructional standards brought about by the general acceptance of DW/142
have virtually negated the requirement for leakage-testing. It is essential to realise that except where it is mandatory this
document is not an endorsement of the routine testing of ducts but purely a guide to outline the procedures for conformity
with the air leakage limits in Table 1. When proper methods of assembly and sealing of ducts are used, a visual inspection
will ordinarily suffice for verification of a well engineered and acceptably airtight construction.
WHERE NOT MANDATORY, DUCT LEAKAGE TESTING IS GENERALLY AN UNJUSTIFIED AND
SUBSTANTIAL EXPENSE.
A.1 INTRODUCTION A.3 LEAKAGE FROM DUCTWORK

Leakage from ducted air distribution systems is an Leakage from sheet metal air ducts occurs at the
important consideration in the design and opera- seams and joints and is therefore proportional to
tion of ventilation and air conditioning systems. A the total surface area of the ductwork in the sys-
ductwork system that has limited air leakage, tem. The level of leakage is similarly related to the
within defined limits, will ensure that the design air pressure in the duct system and whilst there is
characteristics of the system can be maintained. It no precise formula for calculating the level of air
will also ensure that energy and operational costs loss it is generally accepted that leakage will
are maintained at optimum levels. increase in proportion to pressure to the power of
Ductwork constructed and installed in accordance 0.65.
with DW/144 should minimise a level of air leak- The effect of air leakage from high
age that is appropriate to the operating static air pressure/velocity ductwork is critical in terms of
pressure in the system. However, it is recognised system performance, energy consumption and the
that the environment in which systems are risk of high frequency noise associated with leak-
installed is not always conducive to achieving a age.
predictable level of quality in terms of system air-
leakage and it is therefore accepted that designers These problems are less critical with medium
may sometimes require the systems to be tested in pressure/velocity systems, but should be
part or in total. It should be recognised that the considered.
testing of duct systems adds a significant cost to Low pressure/velocity ducts present the lowest
the installation and incurs some extra time within risk in terms of the effect of leakage on the effec-
the programme (See 4.1 and 6.4 re mandatory tive operation of the system.
testing).
A.2 DUCT PRESSURE
Ductwork constructed to DW/144 will be manu-
A.4 SYSTEM LEAKAGE LOSS
factured to a structural standard that is compatible
with the system operating pressure. As there is no direct relationship between the vol-
There are three classes of duct construction to cor- ume of air conveyed and the surface area of the
respond with the three pressure classifications: ductwork system required to match the building
Class A configuration it is difficult to express air leakage
Low pressure ducts suitable for a maximum as a percentage of total air volume.
positive operating pressure of 500 Pascals and Similarly, the operating pressure will vary
a maximum negative pressure of –500 Pascals. throughout the system and as leakage is related to
Class B pressure the calculations are complex. However, it
Medium pressure ducts suitable for a maximum is generally accepted that in typical good quality
positive operating pressure of 1000 Pascals and systems the leakage from each class of duct under
a maximum negative pressure of –750 Pascals. operating conditions will be in the region of:
Class C
Class A low pressure 6%
High pressure ducts suitable for a maximum
Class B medium pressure 3%
positive operating pressure of 2000 Pascals and
a maximum negative pressure of –750 Pascals. Class C high pressure 2%
75
A.5 SPECIFYING AIR LEAKAGE TESTING for the classification for the section of the duct-
Respecting both the cost and programme implica- work that is to be tested.
tions associated with testing ducts for leakage, the The tests shall be carried out as the work pro-
designer may, for example indicate that a particu- ceeds and prior to the application of thermal
lar system is tested as follows: insulation.
a) High pressure ducts – all tested. In the event of test failure of the randomly
b) Medium pressure ducts – 10% of the selected section, the designer shall have the
ductwork shall be selected at random and right to select two further sections at random
tested. for testing. Where successive failures are iden-
c) Low pressure – untested. tified there shall be a right to require the con-
In the case where a random test is selected for tractor to apply remedial attention to the com-
medium pressure ducts the following clause is plete ductwork system.
suggested for inclusion by the designer. The contractor shall provide documented evi-
The designer shall select at random a maxi- dence of the calculations used to arrive at the
mum of 10% of the duct system to be tested for allowable loss for the section to be tested and
air leakage. The duct shall be tested at the the client, or his agent, shall witness and sign
pressure recommended in Table 17 of DW/144 the results of the test.
Table 17 Air leakage rates
Maximum leakage of ductwork

Static
pressure
Low-pressure Medium-pressure High-pressure
differential
Class A Class B Class C
1 2 3 4
Pa Litres per second per square metre of surface area
100 0.54 0.18
200 0.84 0.28
300 1.10 0.37
400 1.32 0.44
500 1.53 0.51
600 0.58 0.19
700 0.64 0.21
800 0.69 0.23
900 0.75 0.25
1000 0.80 0.27

1100 0.29
1200 0.30
1300 0.32
1400 0.33
1500 0.35
1600 0.36
1700 0.38
1800 0.39
1900 0.40
2000 0.42
Note: R e c o m m e n d e d ‘mean’ test pressures are highlighted in bold type with the
actual selection being left to the test operator.
76
A.6 SPECIAL CASES conformity for the pressure class and air leakage
There may be situations on a project where cir- classification for the system under test.
cumstances dictate that special consideration be
given to containing air losses, e.g. a long run of A.9 DESIGNER’S CALCULATIONS
ductwork may incur a disproportionate level of The designer can calculate with reasonable
air loss. accuracy the predicted total loss from a system
In cases such as this example the designer can by:
specify an improved standard of airtightness, i.e. a) Calculating the operating pressure in each
80% of allowable loss for Class ‘B’ ducts. The section of the system.
designer should not specify a Class ‘C’ test at b) Calculating the surface area of the duct-
Class ‘C’ pressure for a Class ‘B’ duct. work in each corresponding pressure
section.
A . 7 SUGGESTED RANGE OF TESTING c) Calculating the allowable loss at the oper-
• High pressure ducts 100% test ating pressure for each section of the sys-
• Medium pressure ducts See A5 tem (see table 17 for allowable leakage
• Low pressure ducts Untested figures).

• Exposed extract systems Untested
• Ceiling void extract
Untested A.10 VARIABLE PRESSURES IN SYSTEMS
systems
• Secondary ducts from Designers can achieve significant cost savings by
VAV or fan coil units Untested matching operating pressures throughout the sys-
• Flexible ducts Untested tem to constructional standards and appropriate
• Final connections and air leakage testing, e.g. the practice of specifying
branches to grilles and construction standards for whole duct systems
diffusers Untested based on fan discharge pressures may incur
unnecessary costs on a project.
A.8 TESTING OF PLANT ITEMS For example, some large systems could well be
Items of inline plant (eg. Figs. 168 to 175) will classified for leakage limits as follows:
not normally be included in an air leakage test. Plant room risers Class C
The ductwork contractor may include such items Main floor distribution Class B
in the test if the equipment has a certificate of Low pressure outlets Class A
77
1.75 1.75
1.5 1.5
1.25 1.25
1.0 1.0
78
Fig. 178 Permitted leakage at various pressures
0.75 0.75
0.5 0.5
0.25 0.25
Leakage in litres per second per square metre duct surface area
0 100 200 300 400 500 600 700 800 900 1000 1200 1300 1400 1500 1600 1700 1800 1900 2000
Pressure difference in pascals

Specim en of air leakage test sheet
*Test No. ......................................
General
Name of job ..................................................................................................................................................

Building reference ..................................................................................................................
Part 1 – Physical details
a Se ction of ductwork to be tested*......................... ....................................................................................
b Su rface area of duct under test†..............................................................................................................
c T est static pressure....................................................................................................................................

d Leakage factor.............................................................................................................................................
e M aximum permitted leakage (b x d)..........................................................................................litres/sec.
Part 2 – Test particulars
a Du ct static pressure reading......................................................................................................................
b Ty pe of flow measuring device................................................................................................................
c R ange of measurement of flow measuring device....................................................................................
d R eading of flow measuringdevice ...........................................................................................................
e Interpreted air flow leakage rate..............................................................................................................
f Duration of test (normally 15 minutes)....................................................................................................
Date of test....................... Carried out by ............................ Witnessed by.....................................
Width and depth

Length Peripheral Area
or diameter
metres millimitres millimitres square metres
†TOTAL
79
AP P E NDI X B – I D E N TI FI C A TI O N OF DUCT WORK
Note
The information given in this Appendix is for the
guidance of mechanical services contractors, con-
sulting engineers, etc. The identification of duct-
work does not form part of the work carried out by
the ductwork contractor unless required by the
designer in the job specification.
B.1 GENERAL possible, where there is adequate natural or arti-

B.1.1 Introduction ficial light.

With the increasing complexity of ventilation and B.2.2 Identification symbols will be needed in
air conditioning systems, it is becoming more plant rooms and remote areas. Symbols should
important to ensure ready identification of ducts occur frequently enough to avoid the need for ducts
for the purposes of commissioning, operation and to be traced back. Symbols should be placed at
maintenance of systems. The purpose of these any service and access points to the distribution
recommendations is to lead towards the use and system, including points where the distribution
standardisation of a system of identification for system has reduced to a single duct.
ducts for the benefit of designers, contractors and B.2.3 Colour coding
clients. The choice of colours has been based on the need
B.1.2 Scope to provide:
B.1.2.1 These recommendations deal with the B.2.3.1 Strong contrasting colours which are
identification of ducts for ventilation, air condi- recognisable even though covered with dust.
tioning and simple industrial exhaust systems.
They do not include piped gas systems such as B . 2 . 3 . 2 Contrast between the symbol colour
those dealt with in BS 1710 1984, nor ductwork and the base colour of the duct. Usually the base
systems for industrial processes, although the colour metallic grey of galvanized or aluminium
general considerations and intentions could be sheet or foil sheathing, or the white, pale grey,
extended with the agreement of the client to or buff paint on the insulation is a neutral colour
cover such systems. against which the recommended symbol colours
will stand out.
B.1.2.2 The method is designed to identify the
air being conveyed, the direction of flow, the B . 2 . 4 The recommended colours are given in
destination of the air and/or the location or Table 18. The colour coding indicates the type of
nomenclature of the plant where the air was air being conveyed.
treated. With small or simple plants, it may not
be strictly necessary to provide identification
because the function is apparent, but it is con-
sidered advisable to do so because this will
increase familiarity with the labelling system Table 18 Recommended duct identification colours
and also because the nature and direction of air
Type Colour BS 4800
flow may not always be apparent.
1 2 3
B.2 IDENTIFICATION
B.2.1 Location Conditioned air Red and 04 E 53
To be effective the identification must be placed Blue 18 E 53
where it can be easily seen and at positions where
Warm air Yellow 10 E 53
identification will be required. To ensure that the
symbols are seen, the following points should be Fresh air Green 14 E 53
considered.
Exhaust/extract/
B.2.1.1 The symbols should be on the surfaces recirculated air Grey 00 A 09
which face the positions of normal access to the Foul air Brown 06 C 39
completed installation.
Dual duct system—
B.2.1.2 The symbols should not be hidden from Red 04 E 53
hot supply air
view by structural members, other ducts, plant,
or other services distribution systems. Dual duct system—
cold supply air Blue 18 E 53
B.2.1.3 The symbols should be placed, where
80
B.2.5 For conditioned air, two symbols (one red, of the plant. The plant itself must be clearly
one blue) may be used, or a single symbol coloured numbered to correspond. Letters for Supply,
part red, part blue. Flow, Extract, etc., should not be added because
B.2.6 If a finer grading than that given in Table 18 identification will be clear from the colour sym-
is required, as for instance in a laboratory with two bol. Thus confusion between ‘S’ for Supply and
separate contaminated air exhaust systems, it is ‘S’ for South will be avoided.
recommended that the type colour be used with, Table 19 Examples of further identification
say, a stripe of a second colour. Where the duct symbols
contents constitute a hazard, a symbol as given in
BS 1710 1984 should be added to the type colour. Code Information given
B.2.7 Direction of flow 9 SW P2 9th Floor,

B-.2.7.1 The form of symbol chosen indicates South-West Zone,
direction. It is an equilateral triangle (see Fig. Plant Two
179) with one apex pointing in the direction of
air flow. Where the boundaries of the duct are Comp 2 P2 Computer 2,
not visible, two triangles should be arranged in Plant Two

line ahead to indicate direction of flow. 3 Lab 8 P4 3rd Floor,
B.2.7.2 The size of the symbol will depend on Laboratory 8,
Plant Four
the size of the duct and the viewing distance.
The recommended minimum size for normal 2 Op Th 2P1 2nd Floor,
use is 150 mm length of side. Operating Theatre 2,
Plant One
Bay 5 N P5 Bay 5, North end,
Fig. 179 Example of duct identification Plant Five
symbol
B.2.8.3 Where identification of the space is by
room number, this must be agreed with the user
who otherwise may have numbered the rooms
differently.
Some examples of further identification systems
are given in Table 19.
B.2.8.4 The letters and numbers should be in
either black or white, whichever gives the better
contrast. They should be marked on the colour
symbol or immediately adjacent to it. The size
Direction of the figures will depend on how easily they can
of flow be seen, but should not be less than 25 mm high.
B.2.9 Explanatory chart

An explanatory chart shall be included in the O
(Operating) and M (Maintenance) manual and
B.2.8 Further identification shall also be kept in the plant room or other con-
B.2.8.1 On small or simple installations where venient place. The chart should show and explain
there is one plant and one or two zones and the colour symbols used on the installation and
therefore little chance of confusing the ducts, it where appropriate the figure and letter codes used
will not be necessary to provide identification for further identification.
other than the colour symbol. On large complex
installations with many zones, widely branched B.3 METHOD OF APPLICATION OF
distribution systems or several plants, further SYMBOLS
identification is necessary. In this connection a B.3.1 Several methods are available for applying
plant refers to the ductwork and equipment the symbols, the main factor being that the symbol
associated with one particular fan. is permanently affixed. Suitable methods are:
B.2.8.2 The further information to be given B.3.1.1 Painting, using stencilled letters and
will normally be the space served by the duct figures.
and in some cases the associated plant. The
B.3.1.2 Self-adhesive plastics or transfers with
information should be given as briefly as pos-
sible using commonly accepted forms such as a water soluble backing. (It is important to ensure
number indicating which floor of a building. that the surface is smooth and clean and that the
The plant identification should always be pre- adhesion will not deteriorate due to the sur-
ceded by the letter ‘P’ to avoid confusion be- rounding atmosphere.)
tween the number of the floor and the number B.3.1.3 Purpose-made plastics or metal labels.
81
AP P E NDI X C – G U I D A N C E N OT ES F OR T HE T RANSPORT ,
HANDLI NG A N D S TO R A G E O F DUCT WORK
It is recommended that before a contract is until they become an integral part of a completed
finalised, that consideration is given to the ductwork system. Whilst this may temporarily
subject of site access, material handling and stor- detract from its intended appearance, this
age as they have a strong influence on the cost deformation will not have any affect on the
efficiency of the overall activity of ductwork functionality of the finally assembled system.
installation.
Installation of ductwork and associated plant
items will inevitably involve manual handling.
C.1 Transport The responsibility of employers and employees to
Large capacity vehicles with high-sided open or assess the risk of personal injury during manual
closed-top bodies are the most suitable for the handling operations is set out in the H.S.E. publi-
transport of ductwork. cation L23, Guidance on Manual Handling Regu-
lations 1992.
Careful consideration should be given to the
unloading of transport on site as not all sites

benefit from the material handling and access C.3 Site storage
facilities that exist in a manufacturing workshop Adequate floor space must be provided within the
such as cranes, fork-lifts or loading bays. Site building for the site storage of ductwork. Such
handling facilities along with vehicular access storage shall make due allowance for the storage
restrictions may influence the type and size of of ductwork in stacks such that access between
transport to be utilised. them is of sufficient width to permit the removal
Lengths of ductwork should be positioned so as to of items without interference to adjoining stacks.
avoid crushing. Lengths with projections, such as Ductwork components should be positioned so as
branches and bends, flanges, girths, damper quad- to avoid crushing. Ductwork of small panel size
rants should be loaded so as to avoid damage to may be stored horizontally; however care should
adjacent duct panels. In some cases, particularly be exercised to ensure that stack sizes are limited
on contracts calling for repetitive sizes, the use of to within the structural strength of the duct sec-
timber jigs and spacers may be justified. tions to prevent distortion of the lower sections
within the stack.
Where reduced bulk and greater protection are
major factors, such as consignments for export,
transporting ductwork in ‘L’ shape sections may C.4 Internal cleanliness of new ductwork
justify the increased site assembly costs. The site storage of ductwork introduces the
important consideration of maintaining the
internal cleanliness of the ductwork. Reference
C.2 Handling should be made to HVCA document:-
To minimise the risk of damage, duct sections
should be clearly identified and deliveries to site • DW/TM2 Guide to Good Practice – Internal
should be closely linked to the installation pro- Cleanliness of New Ductwork Installations.
gramme, so as to avoid accumulation of unfixed
ductwork and minimise double handling. It is If the above conditions can not be satisfied con-
important to recognise that ductwork panels, sideration should be given by the designer to
joints and corners are susceptible to damage and amending the specification to include for “Post
care must be taken when handling such material Installation Cleaning” as covered by the HVCA
through a site. document:-
During handling, individual items of ductwork • TR17 Guide to Good Practice – Cleanliness of
may be liable to slight cross sectional deformation Ventilation Systems.
82
AP P E NDI X D – D U C TW O R K SYST EMS AND F IRE HAZ ARDS
D . 1 Fire and smoke containment/hazards are Method 3 – Protection using Fire Resisting
factors which influence the design and installation Ductwork
of ductwork systems. The ductwork itself forms a protected shaft. The
Information concerning fire protection systems is fire resistance may be achieved by the ductwork
laid down in BS 5588, Fire Precautions in the material itself or through the application of a pro-
design and construction of Building Part 9 (1989) tective material provided that the ductwork has
Code of Practice for Ventilation and Air Condi- been tested and/or assessed to BS476 Part 24 with
tioning Ductwork and tested in accordance with a fire resistance, when tested from either side that
BS 476 Part 20 (1987) and BS 476 Part 22 (1987) should not be less than the fire resistance required
for Fire and Smoke Dampers and British Standard for the elements of construction in the area
476 Part 24 (1987) – ISO 6944 – (1985) for Fire through which it passes. It should also be noted
Rated Ductwork. that the fire resisting ductwork must be supported
with suitably sized and designed hangers, which
D.2 Building Regulations in the United Kingdom
reflect the reduction in tensile strength of steel in
require that new buildings be divided into fire
a fire condition i.e:

compartments in order that the spread of smoke
and fire in the building is inhibited, and to stop the Fire resisting ductwork rated at 60 minutes
spread of smoke and fire from one compartment (945°C), reduces the tensile strength from 430
to another, for given periods of time as specified N/mm 2 to 15 N/mm2.
by the Building Regulations 1991 (Approved Fire resisting ductwork rated at 120 minutes
Document B). (1,049°C) tensile strength reduced to 10 N/mn 2 .
D.2.1 There are three methods of fire protection, Fire resisting ductwork rated at 240 minutes
related to ductwork systems as given in BS 5588
(1,153°C) tensile strength reduced to 6 N/mm2.
Part 9 (1989).
Where the fire resisting ductwork passes through
Method 1 – Protection using Fire Dampers a fire compartment wall or floor, a penetration
The fire is isolated in the compartment of origin seal must be provided which has been tested
by the automatic or manual actuation of closures and/or assessed with the ductwork to BS476 Part
within the system. Fire dampers should, therefore, 24, to the same fire rating as the compartment
be sited at the point of penetration of a wall through which the fire resisting ductwork
compartment wall or floor, or at the point of passes. It should also be noted that where the fire
penetration of the enclosure of a protected escape resisting ductwork passes through the fire com-
route. partment wall or floor, the ductwork itself must be
Fire dampers should be framed in such a way as to stiffened to prevent deformation of the duct in a
allow for thermal expansion in the event of fire, fire to:
and the design must provide for the protection of a) maintain the cross-sectional area of the duct
any packing material included.
b) ensure that the fire rated penetration seal
Standard types of fire dampers and frames are
around the duct is not compromised.
described in Section 22 of this specification.
For further information refer to the impending D.2.2 – Main areas within building where
HVCA publication DW/TM3, ‘Guide to Good Ductwork should be fire protected
Practice for the Design for the Installation of Fire The following notes are for guidance only, and it
and Smoke Dampers’. should be noted that authority rests with the
Building Control Officer and/or the Fire Officer
Method 2 – Protection using Fire Resisting responsible for the building. Reference on the
Enclosures folowing systems should also be made to the cur-
Where a building services shaft is provided rent Building Regulations.
through which the ventilation ductwork passes
and if the shaft is constructed to the highest stan- a. Smoke Extract Systems:
dard of fire resistance of the structure which it If the ductwork incorporated in a smoke
extract system is wholly contained within the
penetrates, it forms a compartment known as a
protected shaft. This allows a complicated multi- fire compartment, it must be capable of resist-
plicity of services to be transferred together ing the anticipated temperatures generated
through the development of a fire. BS 476
through a shaft transversing a number of compart-
Part 24 also requires ductwork, which is
ments and reaching remote parts of the building,
without requiring further internal divisions along intended as a smoke extract, must retain at
least 75% of its cross-sectional area within the
its length. The provision of fire dampers is then
fire compartment. If the ductwork penetrates a
required only at points where the ventilation duct
leaves the confines of the protected shaft. fire resisting barrier, it must also be capable of
providing the same period of fire resistance.
However, if there is only one ventilation duct and
there are no other services within the protected b. Escape Routes covering Stairways, Lob-
shaft, between the fire compartment and the out- bies and Corridors
side of the building, no fire dampers will be All escape routes must be designed so that the
required. building occupants can evacuate the building
83
safely in the case of fire. Ductwork which compartment). Basements with natural venti-
passes through a protected escape route must lation should have permanent openings, not
have a fire resistance at least equal to the fire less than 2.5% of the floor area and
compartment through which the ductwork be arranged to provide a through draft with
passes, either by the use of fire dampers or separate fire ducts for each compartment.
fire resisting ductwork. f. Pressurisation Systems
c. Non Domestic Kitchen Extract Systems Pressurisation is a method of restricting the
Where there is no immediate discharge to penetration of smoke into certain critical areas
atmosphere, i.e. the ductwork passes to of a building by maintaining the air at higher
atmosphere via another fire compartment, fire pressures than those in adjacent areas. It
resistant ductwork must be used. Kitchen applies particularly to protect stairways, lob-
extract ductwork presents a particular hazard bies, corridors and fire fighting shafts serving
as combustible deposits such as grease ‘are deep basements as smoke penetration to these
likely to accumulate on internal surfaces, areas would inhibit escape.
therefore, all internal surfaces of the ductwork As the air supply creating the pressurisation
must be smooth. A fire in an adjacent com- must be maintained for the duration of a fire,
partment, through which the ductwork passes, fire dampers cannot be used within the duct-
could lead to ignition of the grease deposits, work to prevent the spread of fire. Any duct-
which may continue through the ductwork work penetrating fire resisting barriers must
system, possibly prejudicing the safety of the be capable of providing the same period of
kitchen occupants. For this reason considera- fire resistance.
tion must be given to the stability, integrity g. Hazardous Areas
and insulation performance of the kitchen There are other areas within the building
extract duct which should be specifically tested where the Building Control Officer or the Fire
to BS 476 Part 24 for a kitchen extract rating. Officer could state a requirement for fire
resisting ductwork, eg. areas of high risk,
• Access doors for cleaning must be pro- Boiler Houses, Plantrooms, Transformer
vided at distances not exceeding 3 metres.
Rooms etc.
• Fire dampers must not be used.
D.2.3 Cautionary note to all Ductwork
• Use of volume control dampers and tum- Designers/ Manufacturers:
ing vanes are not recommended.
Ductwork constructed to DW/144 Standard has
Further information on kitchen extract systems no tested fire resistance. General purpose ventila-
will be found in the HVCA publication DW/171 tion/air conditioning ductwork and its ancillary
Specification for Kitchen Ventilation Systems. items do not have a fire rating and cannot be either
d. Enclosed Car Parks – which are utilised as or converted into a fire rated ductwork
mechanically ventilated system unless the construction materials of the
Car Parks must have separate and indepen- whole system including supports and penetration
dent extract systems, because of the polluted seals are proven by test and assessment in accor-
nature of the extract air. Due to the fire risk dance with BS 476 Part 24.
associated with car parks, these systems In the case where galvanised sheet steel ductwork
should be treated as smoke extract systems is clad by the application of a protective material,
and therefore maintain a minimum of 75% the ductwork construction must be as type tested
cross-sectional area under fire conditions in and comply with the protective material manufac-
accordance with BS 476 Part 24. Fire dampers turers recommendations, eg. gauge of ductwork,
must not be installed in extract ductwork serv- frequency of stiffeners and non-use of low melt-
ing car parks. ing point fasteners or rivets. Sealants, gaskets and
flexible joints should be as tested and certificated
e. Basements – Ductwork from Basements in accordance with BS 476 Part 24 and comply
must be Fire Rated with the manufacturers recommendations.
If basements are compartmented, each sepa- Careful consideration must also be given to the
rate compartment must have a separate outlet maximum certificated size tested to BS 476 Part
and have access to ventilation without having 24 and the manufacturers recommendations
to gain access (i.e. open a door to another should always be followed.
This appendix incorporates information given in the A.S.F.P publication ‘Fire Rated and Smoke Outlet
Ductwork: An Industry Guide to Design and Installation’ available from Association for Specialist Fire
Protection, Association House, 235 Ash Road, Aldershot, Hampshire GU12 4DD (Telephone: 01252 21322
Fax: 01252 333901)
84
APP E NDI X E – H O T D I P G A LVANIZ ING AF T ER MANUF ACT URE
E.1 General Table 20 Ductwork galvanized after

E.1.1 For Hot Dip galvanizing after the fabrication manufacture – rectangular
of any article it is necessary to appreciate the
nature of the process, including the surface prepa- Maximum Recom- Fig. 10 Fig.18 Maximum
ration of the object to be treated and the precautions duct size mended joint stiffener spacing
(longer sheet rating rating for joints/
to be taken in design, fabrication and handling. side) * *
thickness stiffeners
E.1.2 Hot Dip galvanizing involves dipping the
object into a bath of molten zinc (at a temperature 1 2 3 4 5
of between 445° and 465° C), and it is necessary
mm mm mm mm mm
for the zinc to cover the whole of the surface
leaving no gaps in the coating. 400 1.2 J3 S2 3000
E.2 Design and fabrication
1000 1.6 J4 S3 1250
E.2.1 Rectangular ductwork must be fabricated
using all welded construction techniques with vent- 1600 1.6 J5 S4 800
ed flanges and stiffening frames (see E.2.3) as
mechanical fixing and lock-forming techniques are 2000 1.6 J6 S5 800
not compatible with the galvanising process. In the *This refers to material size only – see E.2.1
course of dipping into the molten zinc bath,
unsightly panel distortion will occur due to the
ever, the pickling process does not generally
relief of inherent stress in the steel sheet or of any
remove grease, oil or oil-based paint, and such sub-
stresses that may have been built into the item dur-
stances should be removed by the fabricator by the
ing fabrication, or indeed of any stresses introduced
use of suitable solvents before the object to be treat-
during the handling, loading or unloading of the
ed is delivered to the galvanizing works. Any sur-
item. Table 20 indicates the minimum requirements
face rust that develops on the object between
for the construction of rectangular ductwork.
the time of treatment by the fabricator and
E.2.2 It is essential to have a free flow of the delivery to the galvanizing works is not important,
molten zinc over the object to be galvanized, to- as this is cleaned off by the acid pickling process.
gether with quick and complete drainage of the
E.4 Handling and storage after galvanizing
molten metal. Because of the high temperature
E.4.1 While a galvanized surface will not develop
involved, the object to be galvanized should be as
rust in the ordinary sense as long as the zinc coating
rigid as possible, either by the use of sufficiently
is undamaged, zinc is subject to what is known as
heavy sheet or by stiffening or bracing, or both.
‘wet storage stain,’ which is a white powdery
E.2.3 Any sealed hollow section or cavity must deposit on the zinc surface. Wet storage stain can
be adequately vented in order to obviate any pos- arise from the stacking of articles when wet, acid
sibility of explosion. Holes of sufficient size (See vapours, the effect of salt spray, the reaction of
E.2.4) in vertical members must be provided dia- rain with flux residues, etc.
gonally opposite each other, top and bottom of the
The damage to the zinc coating is negligible in
member.
most cases. When the deposits are heavy, these
E.2.4 Vent holes should be of sizes as follows: should be removed by brushing with a stiff bristle
Size of Minimum or wire brush.
hollow diameter of E.4.2 Galvanized articles should therefore not be
section vent end stacked or loaded when wet; they should preferably
(dia. or side) drainage holes be transported under cover or shipped in dry, well
mm mm ventilated conditions, inserting spacers (but not
Up to 25 10 resinous wood) between the galvanized articles.
50 to 100 16 E . 4 . 3 When stored on site or elsewhere, care
100 to 150 20 should be taken to avoid resting the galvanized
Over 150 25 article on cinders or clinker, as the acid content of
E.2.5 Stiffeners should desirably have their these substances will attack the zinc surface.
corners cropped so as to allow a free flow of zinc.
E.5 Subsequent finishing
Stiffeners should be rolled steel angle, uncoated.
E.5.1 Paint finishing subsequent to galvanizing is
E.3 Surface preparation before galvanizing sometimes required either for additional protec-
E.3.1 The steel surface to be galvanized must be tion or for decorative reasons. Galvanised sur-
chemically clean before dipping to ensure a contin- faces require chemical pretreatment prior to paint-
uous coating. This is mainly achieved at the galva- ing. Examples of such a treatment are T-Wash and
nizer’s works by pickling in an acid bath and flux- Etch Primer Types. Advice should be sought from
ing before the article goes into the zinc bath. How- the paint manufacturer.
This Appendix incorporates information given in publications available from the

Galvanizers’ Association, 6 Wrens Court, 56 Victoria Road, Sutton Coldfield, West Midlands B72 1SY
85
AP P E NDI X F – S TA I N LE S S S TEEL F OR DUCT WORK
F.1 General usually adjusted by the manufacturer to balance

F.1.1 Stainless steel is not a single specific mate- forming response, weldability and corrosion
rial: There is a large family of stainless steels with resistance. It is readily welded in thin sheet form
varying compositions to suit specific applications, and, since it does not form a hardened weld
but all contain at least 11% of chromium as an HAZ, no post-weld heat treatment is required. It
alloying addition. is widely used for automotive exhaust system
F.1.2 Modern stainless steels have a combination parts and is suitable for a range of ducting and
of good formability and weldability, and can be structural applications in mildly corrosive
supplied with a variety of surface finishes (see applications.
F.4.1 below) They have been developed to cover a F.2.2.2 17% chromium ferritic steel, 430S17,
wide range of structural uses where high resis- New Designation 1.4016, x6Cr17.
tance to corrosion and low maintenance costs are
Forming and general characteristics are similar
demanded.
to the 409 grade, but the higher chromium level
F.1.3 Ductwork applications for which stainless confers better general corrosion resistance.
steels are particularly suited include those where a

high integrity inert material is essential; where a F.2.2.3 18% chromium, 9% nickel austenitic
high degree of hygiene is required; in the chemi- stainless steels.
cal industries where toxic or hazardous materials A widely used grade is 304S15, New Designa-
may be contained; in nuclear and marine application 1.4301, x5CrNi18-10. There are composi-
tions (e.g. on offshore platforms). Stainless steels tional variants within this family, designed to
also find application in exposed ductwork where give specific formability and welding character-
their finish can be used to aesthetic advantage. istics. All are weldable and have good general
corrosion resistance to normal and mildly corro-
F.2 Grades of stainless steel
sive atmospheres. They are ductile and
F.2.1 The grades of stainless steel most common-
formable, but forming loads are higher than for
ly used for ductwork applications are among those
mild steels and suitable, robust equipment is
covered currently by BS 1449, Part 2. However, a
required.
European Standard, will supersede this British
Standard. New designations of the most common F.2.2.4 17% chromium, 11% nickel, 2%
steel grades are given in Table 21. molybdenum austenitic steel, a widely used
In some cases there are minor differences in grade of this type is 316S31, New Designation
chemical composition between the BS and EN 1.4401, x5CrNiMo17-11-2.
grades. This steel has a significantly higher corrosion
Before a grade is specified, the nature of the resistance than the standard 18% chromium, 9%
interior and exterior environments of the duct- nickel steels and is suitable for use in more
work system should be taken into account. The aggressive environments such as are met in
steels described below cover most normal appli- ductwork in process plants. However, more
cations. However, advice on specific corrosion highly alloyed stainless steels with better corro-
risks should be taken if the ductwork is to be sion resistance are also available and the advice
installed in a chemically contaminated atmos- concerning aggressive environments given
phere, or is to be used to transport contaminated under section F.2.1 above should be noted.
air, particularly if there is a risk of internal con-
densation. More highly alloyed grades of stainless F.3 Availability
steel with enhanced corrosion resistance are avail- Stainless steel is supplied in a wide range of thick-
able if required. nesses, from 0.4 mm for cold-rolled sheet and
The commonly used steels divide into two main coil, and from 0.075 mm for precision rolled strip.
families; the lower alloy ferritic 11-18% chromi- It is supplied in slit widths as specified by the cus-
um stainless steels are magnetic. The austenitic, tomer, up to a maximum width of 2030 mm,
18% chromium, 9% nickel steels have generally depending on thickness.
better corrosion resistance and are non- or only Material compatability of sheet, section and fix-
slightly magnetic. ings is not always assured in practice due to com-
F.2.2 The more commonly used stainless steels mercial availability.
and their characteristics are described below.
F.2.2.1 11.5% chromium ferritic steel with a F.4 Surface finishes
titanium addition, 409S19, New designation F.4.1 Stainless steel is available in a wide selec-
1.4512, X2CrTi12. tion of finishes, varying from fine matt to mirror
polished, as defined in BS 1449: Part 2: and in
This, and related grades, are among the leanest EN10088: Part 2.
alloyed of the stainless steels. Forming charac-
teristics are similar to those of mild steel, so it Mill finishes
can be worked using conventional practices. Type 2D Cold finished softened and
The composition and processing of the steel is descaled. A uniform matt finish.
86
Type 2B Cold rolled, softened, descaled essary, however, depending on the type of stain-
and lightly worked with polished less steel being used.
rolls. A smooth finish brighter F.6.3 As a general rule, the 400 series of stainless
than 2D. steels can be formed using normal mild steel set-
Type 2A/2R Bright annealed. A cold finished tings. The 300 series, however, because of the
reflective appearance retained higher yield point and the greater rate of work
through annealing. hardening, will require higher working pressures.
Polished finishes F.6.4 Ductwork contractors who have experience
Type 4/2J Dull polished. A lustrous uni- of the use of stainless steel report difficulty in
directional finish produced by forming Pittsburgh and button punch snap lock
fine grinding, generally with seams. As regards cross joints, socket and spigot
abrasives of 150 grit size. It has joints are recommended, and one or two of the
little specular reflectivity. slide-on flanges are suitable. In view of the fore-
Further dull polishing after fabri- going, it is recommended that trials be carried out
cation will diminish the effects before starting on production.
on appearance of welds or acci- F.7 Rectangular ducts

dental damage by blending them The constructional requirements for rectangular
into the surrounding metal. stainless steel ducts are the same as for galvanized
Type 5/2K Dull polished with specific mild steel.
requirements, to achieve a fine, F.8 Circular ducts
clean cut surface finish with The constructional requirements for circular stain-
good corrosion resistance. less steel ducts are the same as for galvanized
Type 8/2P Mirror polished. A bright, non- mild steel.
directional reflective finish with F.9 Stiffening
a high degree of image clarity. Wherever possible, the material used for stiffen-
F.4.2 Where other finishes are required, such as ing should be of the same grade of stainless steel
for aesthetic purposes, a range of patterned or tex- as used for the construction of the ducts, or should
tured (2F,2M) finishes is available. Colour may be be made equally corrosion resistant to suit the
applied in the form of paint or lacquer, or the environment in which the ductwork is situated.
material may be supplied pre-coloured as by the F.10 Fixings and fastenings
‘INCO’ process or by mill application of polymer The types of fastening and the maximum spacings
coatings. specified in Table 5 (rectangular) and Table 9 (cir-
cular) also apply to stainless steel ductwork.
F.5 Surface protection
F.5.1 No surface protection is required for stain- Fixings and fastenings should be of the appro-
less ductwork used indoors or outdoors, provided priate grade of stainless steel as used in the con-
the correct quality is specified. This is because the struction of the ductwork, or should be made
naturally occurring chromium-rich oxide film equally resistant to corrosion in relation to the
which is present on the surface of the metal, if environment in which the ductwork is situated.
damaged, reforms immediately by reaction The type of stainless steel fastening used should
between the steel and the atmospheric or other conform to the appropriate specification BS 6105:
source of oxygen. 1981.
F.11 Welding
F.5.2 If a mixture of metals is used, such as mild
All the modern welding processes may be used to
steel supports for stainless steel ductwork, the sur-
weld stainless steel but carburising operations
face of the mild steel must be adequately protected
such as oxy-acetylene and carbon arc welding are
from the galvanic corrosion that might result from
not suitable. The Tungsten inert gas (TIG) and re-
the intimate contact between the two types of
sistance welding techniques are most likely to be
metal. (The appropriate protective finish should
used for thin gauge materials. Attention is drawn to
be employed. See 27.3.5)
BS 4872: Part 1 1982, (welder qualification) and
BS 7475: 1991 (welding processes).
F.6 Construction
F.6.1 Sheet thicknesses for stainless steel duct- Selection of the correct welding electrodes and
work should be the same as for galvanized steel filler rods is important, particularly when
(see Tables 2, 3 and 4). Provided the correct grade w e l d i n g d i s s i m i l a r m e t a l s , such as stainless
of stainless steel has been selected, there is no steels to non-stainless structural steels. Reference
requirement for a corrosion allowance with stain- for guidance should be made to BS 2901: Part 2:
less steels and the gauge can be selected on struc- 1990 for rods and wires for gas shielded welding
tural considerations only. and BS 2926:1984 for electrodes for Manual
Metal Arc. (MMA) welding.
F.6.2 The forming of rectangular and circular
ducts can be carried out by the use of conventional F.12 Avoidance of contamination
press working and sheet metal forming machines. Attention is drawn to the risks of rust staining of
Some alteration in working practices may be nec- stainless steel surfaces resulting from contamina-
tion by non-stainless steel or iron debris.
87
If particles such as filings of a non-stainless steel F.13 Fire dampers
or iron are expressed into contact with a stainless Stainless steel is an ideal material for use in the
steel, subsequent exposure to moisture will lead to construction of fire dampers, because of its high
staining of the surface as these particles rust. resistance both to heat and corrosion. It is there-
Whilst this staining often can be removed without fore most applicable where a fire authority speci-
harm to the stainless steel surface, in aggressive fies a requirement for corrosion resistance.
environments corrosion products around the rust F.14 Sealants, gaskets and tapes
centre can create a risk of pitting of the stainless The sealing materials and methods set out in this
steel. As a general rule, stainless steels should be publication are also applicable to stainless steel
kept free from iron dust and debris contamination. ductwork. However, any chloride-based material,
In particular, wire brushes must be made of stain- such as polyvinyl chloride (PVC), should be
less steel and shot, beads and abrasive media used avoided, as breakdown of such material at certain
to clean surfaces must be ‘iron free’. elevated temperatures could lead to corrosion of
the stainless steel.
Contamination can arise from tools which have F.15 General design considerations
been used previously for cutting non-stainless It is the designer’s responsibility to indicate the
steels without adequate cleaning and from abra- type of stainless steel most suitable for the condi-
sion on stillages and racks. It is good practice to tions to which the ductwork is to be exposed. If
dedicate storage and bench areas for stainless users and designers are in doubt as to which mate-
steels, with soft surfaces, e.g. wooden battens, to rial is appropriate to a particular application, tech-
mininise scratching of the surface and if practic- nical advice may be obtained from the source
able designate stainless only working areas. noted below.
Table 21, showing the approximate correspondence between the chemical compositions of the com-
monly used stainless steel grades in BS 1449, Part 2: 1983, and the European Standard EN 10088-1,
List of Stainless Steels. (Part 1 gives the chemical compositions and identifications of the stainless
steels, it is for information. Part 2 of this standard describes the technical delivery conditions for
sheet/plate and strip for general purposes.)
Grade Designation, Grade Name and Fit on chemical composition

BS 1449 pt 2: 1983 Number in EN10088-1 between standards
409S19 x2CrTi12 1.4512 wider
430S17 x6Cr17 1.4016 close fit
304S15, x5CrNi18-10 1.4301 wider
304S16 close fit
304S31
304S11 x2CrNi18-09 1.4307 wider

x2CrNi19-11 1.4306 wider
316S11 x2CrNiMo17-12-2 1.4404 close fit
316S31 x5CrNiMo17-12-2 1.4401 close fit
This appendix is based largely on information kindly

supplied by the
Avesta Sheffield Technical Advisory Centre, ASTAC,
P.O. Box 161,
Shepcote Lane,
Sheffield S9 1TR
Telephone: 0114 244 0060 Fax: 0114-242 0162
88
APPENDIX G - PRE-COATED STEEL
G.1 Nature of the material G.5 Ductwork construction from pre-coated steel
G.1.1 ‘Pre-coated’ steel is sheet, coil or strip to G.5.1 The type of pre-coated steel most suitable
which has been applied at the steel mills a coating for ductwork should be carefully considered,
having a decorative or protective function, or both. mainly from the point of view of the fabrication
properties of the coating type. It is probable that a
G.1.2 The basis metal to which the coatings are
plastisol coating will be found to be most suitable
applied are hot-dip galvanized or aluminium-zinc
for ductwork, as this type of coating will withstand
coated sheet or coil, uncoated steel or electro-
forming at normal ambient temperatures. It also
galvanized steel (e.g., Zintec).
tolerates rougher handling during forming and
G.2 Range of coatings available erection than the much thinner paint coating types.
G.2.1 A number of different types of coating, in G.5.2 Careful consideration should be given to
various thicknesses, are available – PVC the constructional methods to be used for duct-
(‘Plastisol’ and ‘Organosol’); paint coatings of work to be made from pre-coated steel. The
several types, silicone enamels, etc. principle to be followed should be to make seams
G.2.2 A wide range of colours and surface fin- and joints as unobtrusive as possible. Some of the
ishes are available, but there are minimum quan- conventional methods of seaming may be used,
tity requirements for some types of coating, finish but a number of others are not suitable. Welding
and colour. The characteristics of the particular with conventional equipment should not be
type of coating contemplated for a particular use attempted. Mechanical fastenings should be
should be investigated in respect of formability, chosen with care having regard to appearance as
fastness to light, chemical resistance and other well as efficiency; and sealant should be applied
relevant properties. with these factors in mind. Stiffening should be
carefully considered in relation to appearance.
G.2.3 The material can be supplied with one or
both sides treated, with the specified coating. G.6 Handling, storage, transport and erection
Standard ‘backing coat’ finishes are usually G.6.1 Much more care than usual is required in
applied to the reverse side unless otherwise these respects, as the coatings are all to a greater
stated. or lesser degree susceptible to mechanical damage.
For example, sheet should not be dragged off
G.3 Sizes available the top of a pile but removed by ‘turning’ off the
G.3.1 Pre-coated steel is available in sheet or coil stack.
form. The maximum available width can vary
G.6.2 With sheet pre-coated on one side only, it
according to the steel thickness required.
may be found desirable to stack face to face.
Availability varies according to type of substrate
and coating, so prospective purchasers should G.6.3 The flexibility of coatings of the types used
query the sizes available for the specific type on pre-coated steel depends on temperature.
required. Therefore, manipulation should be carried out at
temperatures above 16°C (60°F) in order to minimise
G.4 Sources of supply the risk of the film cracking on roll forming, etc.
G.4.1 Pre-coated steel is widely available but it If the material has been stored outside at low
should be noted that minimum order quantities temperature, a warm-up period should be allowed
may apply. before manipulation of the sheet is undertaken.
The information on which this appendix is based

has been kindly supplied mainly by British Steel
plc. More detailed information may be obtained
from:
British Steel plc,
Product Development Centre,
Shotton Works,
Deeside,
Flints CH5 2NH
Telephone: Chester (01244) 812345
Fax: 01244 836134
89
APPENDIX H – ALUMINIUM DUCTWORK
H.1 Scope H.5 Fastenings

This section applies only to rectangular and circu- H.5.1 The types of fastening and the maximum
lar aluminium ductwork operating at low pres- spacings specified in Table 5 (rectangular) and
sure, as defined in Tables 22 and 23. Table 9 (circular) apply to aluminium ductwork,
If consideration is being given to either higher except that such fastenings shall be of aluminium,
pressures or flat oval ductwork then it would be stainless steel or monel metal.
prudent to seek advice from manufacturers who
H.6 Welding
have the experience and capacity to manufacture
H.6.1 All the aluminium alloys can be welded by
aluminium ductwork.
MIG (Metal and Inert Gas) or TIG (Tungsten and
H.2 Suitable grades Inert Gas) methods, with argon as the shielding
H.2.1 Ductwork can be constructed from all the gas. Helium or a mixture of helium and argon can
commonly used aluminium alloys, the choice be used, but not C0 2 . Alloys in a work-hardened
depending on the purpose for which the ducts will temper are reduced to the annealed condition in
be used and the service environment. the heat affected zone; 6082-T6 is reduced approx-
imately from the T6 to the T4 temper. Alloys 1200

H.2.2 The alloys 1200, 3103 and 5251 (as speci-
and 3103 are easy to braze, as is 6082, but the latter
fied in BS.EN485, BS.EN515, BS.EN573) are
needs to be re-heat treated to regain its strength.
easy to form and to join, and have excellent resis-
tance to atmospheric corrosion, with 5251 being
rather more resistant to marine atmospheres. H.7 Protective finishes
H.7.1 No protective finishes are required for alu-
H.2.3 These alloys can be supplied in various minium ductwork used indoors or outdoors in
tempers produced by different degrees of cold roll- normal atmospheric conditions. In moist atmos-
ing, so that a range of strengths is available. In pheres, particularly if they are contaminated by
choosing a temper, it is necessary to consider any industrial effluent or by salt from the sea, surfaces
forming that will be done, as with the harder not exposed to washing by rain will become
tempers the forming of tight bends might cause roughened and covered with a layer of white cor-
cracking. Where high strength is required, alloy rosion product. However, this has the effect of
6082-T6 sheet can be used. sealing the surface against further attack, and the
H.2.4 Aluminium coil is available in plain form mechanical properties of any but the thinnest of
and pre-painted finish. materials will be only slightly affected.
H.7.2 If surface protection is specified, any of the
H.3 Construction – rectangular ducts
H.3.1 Table 22 sets out the minimum constructional normal organic finishes can be used, including the
and stiffening requirements for rectangular alumin- laminated PVC films, although paints with heavy
metal pigments are not suitable. The use of pre-
ium ducts and the permitted types of cross joint.
painted strip in coil form provides a reliable qual-
H.3.2 Sealant ity finish and often proves more economical than
The sealant requirements set out in this specifi- painting after assembly. Anodising provides an
cation for galvanized steel rectangular ductwork excellent finish for aluminium, but this process
also apply to the longitudinal seams and cross would have to be carried out after forming and
joints in aluminium ductwork. would therefore not usually be practicable for
H.4 Construction - circular ducts ductwork, except perhaps for ducts formed from
H.4.1 Table 23 sets out the minimum construc- extrusions.
tional and stiffening requirements for circular H . 7 . 3 Mild steel section used in supporting
ducts made from aluminium, and the permitted aluminium ductwork shall have a protective finish
types of cross joint. (See 27.3.5).
Table 22 Rectangular aluminium ducts – low pressure constructional requirements
Maximum spacing Minimum
Maximum Minimum between joints/stiffeners aluminium
Suitable angle section
duct size sheet With cross
cross-joints Plain
(longer side) thickness for cross-joints
breaking or
sheet and stiffeners
pleating
1 2 3 4 5 6
mm mm Figs mm mm mm
400 0.8 13, 14 – – –
600 0.8 10 - 12, 15 - 17 1500 – 25 x 25 x 3
800 1.0 10 - 12, 15 - 17 1200 1500 30 x 30 x 4
1000 1.0 10 - 12, 15 - 17 800 1200 40 x 40 x 4
1500 1.2 10 - 12, 15 - 17 600 800 40 x 40 x 4
2250 1.2 10, 11 600 800 50 x 50 x 5
3000 1.6 10, 11 600 600 60 x 60 x 5
90
Table 23 Circular aluminium ducts (spirally-wound and straight-seamed) – low
pressure constructional requirements
Spiral-wound duct Straight-seamed duct Minimum aluminium

angle section for cross
joints and stiffeners
Normal Minimum Normal Minimum
Cross Cross
sheet stiffening sheet stiffening Duct
joints joints
thickness requirements thickness requirements angle
diameter
mm mm
as for figs as for as for figs as for 800 25 x 25 x 3

galvanised 32 - 38 galvanised galvanised 39 - 45 galvanised 30 x 30 x 3
1000
duct with LP duct duct with LP duct
Table Limits Table Table 8 limits Table 1500 40 x 40 x 4
7 7 Col. 2 8
Incorporates information provided by the

Aluminium Federation Ltd., Broadway House,
Calthorpe Road, Five Ways, Birmingham B15 1TN
(telephone: 0121-456 1103) from whom more
detailed information may be obtained.
APPENDIX J – EUROVENT
J.1 General tate commercial exchanges between its member

Some explanation of the function, composition, nations in the search for improved quality; and the
objectives and membership of EUROVENT is adoption of rules, directives and codes of practice
given below. in the technical and economic spheres in the
member countries’.
J.2 Membership
EUROVENT is an omnibus word standing for the J.4 EUROVENT publications
European Committee of the Construction of Air EUROVENT has published a number of docu-
Handling Equipment. The committee was formed ments in the air handling field, and these include
in 1959, and in 1977 its constituent members were Document 2/2 covering the procedure for testing
the relevant national associations in Austria, for air leakage in ductwork, and provides for two
Belgium, Denmark, Finland, France, German levels of permissible air leakage for low-pressure
Federal Republic, Italy, Netherlands, Norway, air distribution systems. Document 2/3 covers the
Sweden, Switzerland and the United Kingdom. standardisation of duct sizes.
J.3 Objectives J.5 Air leakage

The objectives of EUROVENT are ‘to improve and The basis on which air leakage is calculated in
develop technical matters in the manufacture and EUROVENT Document 2/2 has been adopted in
operation of air handling equipment; to improve DW/143 A practical guide to Ductwork Leakage
the professional status of its members and to facili- Testing.
Information about EUROVENT may be obtained

from the HEVAC Association, Sterling House, 6
Furlong Road, Bourne End, Bucks SL8 5DG
(Telephone: 01628 531186 Fax: 01628 810423)
91
APPENDIX K – SUMMARY OF BS.EN10142: 1991 CONTINUOUSLY
HOT-DIP ZINC COATED MILD STEEL STRIP AND SHEET
FOR COLD FORMING
Note – The extracts from BS.EN10142: 1991 have Normal spangle (N). This finish is obtained when
been prepared by the HVCA and are included here the zinc coating is left to solidify normally. Either
by courtesy of the British Standards Institution. no spangle or zinc crystals of different sizes and
K.1 GENERAL brightness appear depending on the galvanizing
K.1.1 The BS 2989: 1975 and 1982 entitled conditions. The quality of the coating is not
‘Continuously hot-dip zinc coated and iron-zinc affected by this.
alloy coated steel: wide strip, sheet/plate and slit NOTE. Normal spangle is the type normally sup-
wide strip’ summarised in DW/142 has been plied for a wide variety of applications.
superseded by BS.EN10142: 1991 entitled Minimized spangle (M). The surface has mini-
‘Continuously hot-dip zinc coated mild steel strip mized spangles obtained by influencing the
and sheet for cold forming’ (including amendment solidification process in a specific way. The finish
A1:1995). may be specified if the normal spangle applicable
K.1.2 British Standard BS.EN10142: 1991 sets does not satisfy the surface appearance
out requirements for the conventional galvanized requirements.
sheet and coil and for zinc-iron coated steel. (Both
K.5 SURFACE PROTECTION
these are included in DW/144 - see Section 7.)
K.5.1 General
The type of steel normally used for ductwork is Hot-dip zinc coated strip and sheet products
DX51D and Z275.
generally receive surface protection at the pro-
K.2 STEEL GRADES ducer’s plant. The period of protection afforded
K.2.1 BS.EN10142: 1991 and amendment depends on the atmospheric conditions.
A1: 1995 lists the grades of steel set out in the next
K.5.2 Chemical Passivation
column, among others:
Chemical Passivation protects the surface against
Grade Name of grade Application 1 humidity and reduces the risk of formation of
DX51D + Z Bending and Forming quality ‘white rust’ during transportation and storage.
profiling steel suitable for Local discolouring as a result of this treatment is
quality manufacture of permissible and does not impair the quality.
the most profiles
and more difficult K.5.3 Oiling
bending operations This treatment also reduces the risk of corrosion
of the surface. It shall be possible to remove the
DX52D + Z Drawing quality Forming quality
oil layer with a suitable degreasing solvent which
steel suitable for
does not adversely affect the zinc.
simple drawing
operations and for K.5.4 Chemical Passivation and Oiling
more difficult pro- Agreement may be reached with the producer on
filing operations this combination of surface treatment if increased
DX53D + Z Deep drawing Forming quality protection against the formation of ‘white rust’ is
quality steel suitable for required.
deep drawing and
K.5.5 Untreated
difficult forming
Hot-dip zinc coated strip and sheet products com-
operations
plying with the requirements of this standard are
DX54D + Z Special deep Forming quality only supplied without surface protection if
drawing quality steel suitable for expressly desired by the purchaser on his own
deep drawing and responsibility. In this case, there is increased risk
difficult forming of corrosion.
operations where
a non-ageing steel K.6 FORMING
is required K.6.1 The British Standard says that provided
K.3 COATING TYPES AND TOLERANCES that the profiling machine is set to avoid excessive
K.3.1 The types of zinc coating are set out in stretching in the product, it is possible to form
Table 24. BS.EN10142: 1991 (reproduced at the lock seams successfully with DX51D + Z sheet up
foot of this summary). to a thickness of 1.5 mm and DX52D + Z sheet up
to 2 mm; and snap lock seams with DX51D + Z up
K.3.2 Whilst the coating thickness is not subject
to 0.9 mm thick sheet and DX52D + Z sheet up to
to tolerances the substrate and consequently the
2 mm.
gauge thickness does have accepted tolerances
and these including sheet widths/lengths will be K.7 WELDING
found in BS.EN10143: 1991. K.7.1 Care should be taken to use proper
K.4 COATING FINISHES methods and procedures. The iron-zinc coating is
K.4.1 BS.EN10142: 1991 and A1 1995 includes a more suitable for resistance welding than the con-
description of the various types of finish available: ventional zinc coating.
92
Table 24 (Extract from BS.EN10142: 1991) Coating mass (weight)
Minimum coating mass
(including both sides
Coating designation Suggested applications (see note 2)
Triple Single
spot test spot test
g/m2 g/m2
Zinc coatings (Z)
Light – for use where corrosion conditions are
Z100 100 85 not severe and/or where forming
Z200 200 170 operations preclude heavier coatings.
Z275 275 235 Standard
Z350 350 300
450 Heavy duty – for longer life relative to
Z450 385
Heavy duty – standard and light coatings.
Z600 600 510
Zinc-Iron alloy coatings (ZF)

100 Iron-zinc alloys – alloyed coatings of iron and zinc
ZF100 85
for easy painting and particularly
ZF180 180 150
resistance welding.
Note 1. The mass of zinc is not always equally distributed on both surfaces of the sheet. However, it can
normally be expected that not less than 40% of the specified minimum coating mass, as determined by
the single spot test, will be found on each surface.
Note 2. The suggested applications included in the right-hand column of the above table are those provided by
British Steel PLC.
APPENDIX L – ‘DESIGN NOTES FOR DUCTWORK’

(CIBSE Technical Memorandum No. 8)
L.1 At the time of publication (1983) this techni- Standard dimensions of circular, rectangular
cal memorandum brought together information on and flat oval ducts.
the design of ductwork systems. Duct sizing methods, including velocity, equal-
L.2 The contents had been drawn from the rele- friction and static regain methods, and pressure
vant sections of the CIBSE Guide and other loss calculations, with an example calculation.
recognised references, and include additional
material on good design practice. The Notes make Heat loss from and gain to air in the duct; con-
frequent reference to DW/142, and an effort was densation, noise control and fire.
made to ensure consistency between the two pub- Commissioning and testing.
lications. Whilst DW/142 has now been superced-
Overseas work.
ed by DW/144, the technical memorandum, has
not currently been up-dated but still contains rele- Drawing symbols in current use.
vant information that may be of use to a ductwork L.3 The flow of heavily contaminated air in ducts
designer/manufacturer. Whilst some of the infor- is not covered in detail in the Notes; nor are the
mation may now be superceded, TM8 includes constructional aspects of ductwork, which are
chapters on:
dealt with in DW/144.
Pressure loss in ducts, including corrections for
duct surface type, air pressure, air density, tem- L.4. The Notes were completed by references, a
perature and altitude, and loss factors for fit- bibliography of over thirty titles and appendices
tings. covering properties of air, ductwork support
Equivalent diameters of rectangular and flat loads, velocity pressure for air flow and conver-
oval ducts. sion to SI units.
Technical Memorandum No. 8 was published by the Chartered Institution of Building Services Engineers,
Delta House, 222 Balham High Road, London SW12 9BS (Telephone: 0181 675 5211)
and whilst it is no longer available as a publication, it is still available in photo-copy form.
93
t E
-
TO22342
_____ 0000853. -593
~-
E
___ -
APPENDIX M - GUIDANCE NOTES FOR INSPECTION, SERVICING

M.l GENERAL ii) Clear directions could be given to the duct-
This appendix highlights, in summary form, the work contractor as to the size and location
access consideration that should be made by the of cleaning access panels that are required to
designer in terms of inspection, servicing and be fitted during the manufacturing process.
cleaning. Having considered the scope and the iii) The specialist cleaning operation prior to
design of the ductwork system relative to the commissioning would enable the cleaning
guidelines outlined below the designer should contractor to verify the practical access
clearly indicate which levells of access should be requirements for the future cleaning opera-
incorporated into the manufacture of a new duct- tions associated with a regular maintenance
work system (See Table 25 and Note 1 below it). programme.
M.2 DESIGN CONSIDERATIONS
iv) A specialist cleaning operation prior to com-
M.2.1 Inspection and servicing requirements are
missioning would allow the designer to omit

set out in Section 20 of this specification. from the specification the DW/TM2 require-
M.2.2 Cleaning requirements are set out in the ments for factory sealing, protection, wipe
HVCA publication TR17 “Guide to Good downs and capping-off.
Practice, Cleanliness of Ventilation Systems” and
the guide states “The precise location, size and v) Specialist cleaning to the measurable stan-
type of access would be dependent on the type of dards defined in TR17 will allow an objec-
ductwork cleaning, inspection and testing meth- tive definition of cleanliness to be achieved.
ods to be adopted.” Careful consideration must be given by the
Care, protection and standards of cleanliness prior designer to the practical problems associated with
to commissioning are set out in the HVCA publi- the manufacture and fitting of suitably sized access
cation DW/TM2 “Guide to Good Practice, panels on small cross section ducts and the circu-
Internal Cleanliness of New Ductwork lar faces of round and flat oval ducts in particular.
Installations” and the guide states “Where specif-
M.2.3 Special consideration must be given by the
ic limits of cleanliness are required, ductwork
designer to the practical problems associated with
shall be cleaned after installation by a specialist
gaining personnel access to heavily congested ceil-
cleaning contractor.”
ing areas and multi-layered ductwork systems.
It will be in the interests of the designer, both This approach would avoid the possibility of
financially and practically, to consider employing access panels being incorporated into a ductwork
a specialist cleaning contractor at the outset of a system at the manufacturing stage that were later
contract to internally clean newly installed duct- found in practice to be inaccessible for either ser-
work prior to handover. This approach would vicing or cleaning activities.
realise the following benefits:-
i) The actual number of cleaning access panels M.3 ACCESS TO IN-LINE EQUIPMENT
could be determined to suit the method of This appendix only covers accesdinspection
cleaning to be adopted (This may be less through the ductwork body adjacent to an item of
than the maximum requirements listed in-line equipment and not openings in the equip-
under Level 3 of Table 25). ment itself.
Table 25 Access requirements for inspection, servicing and cleaning
HVCA PUBLICATION REFERENCE
Adjacent Guide to Good Practice
in-line DWl144 Cleanliness of Ventilation Systems
itemslequipment Level 1 Level 2 Level 3

InspectiodServicing Section ref Cleaning Survey/Inspection Panels Cleaning
20.1.1 (minimum size subject to duct size) Access Panel!
Control Dampers One (inspection) 20.3 One 300mm x 200mm Both sides
Fire Dampers One (servicing) 20.2. I . I One 300mm x 200mm One side
HeatingKooling Coils One (inspection) 20.2.1.3 One 3OOmm x 2 0 0 m (upstream) Both sides
Attenuators (rectangular) None required One 300mm x 200mm (downstream) Both sides
Attenuators (circular) None required One 300mm x 200mm (downstream) One side
Filter Sections One (inspection) 20.2.1.2 None required Both sides
Air Turn Vanes None required - None required Both sides
Changes of Direction None required None required One side
In-Duct FansiDevices One (inspection) 20.2.1.3 None required Both sides
94
to be fitted as close as practically possible to the
A P P E N D I X M (Revised) 'obstruction' and then at 10 metre intervals from that
point until the next internal 'obstruction' occurs.
Guidance notes for NOTE! Kitchen extract systems, with panels at 3 metre
inspection, servicing and intervals, and vertical ductwork, with a panel at
the bottom and top of each riser, are the only
cleaning access exceptions to panels being at 10 metre intervals.
openings b) The designer should identify any 'obstruction' or
item of equipment that requires an access panel on
M.1 General both the upstream and downstream side duct con-
This appendix highlights, in summary form, the access nections with the upstream panel being used as the
considerations that should be made by the designer in start point measure for any subsequent panels as
terms of inspection, servicing and cleaning. Having con- referred to in (a) previously
sidered the scope and the design of the ductwork system
relative to the guidelines outlined below, the designer

The minimum requirements in (a) and (b), if specified by
should clearly indicate the access requirements that are to
the designer, negates the requirement for panels to be
be incorporated into the manufacture of a new ductwork
provided at 'changes of direction' in the ductwork system
system.
i.e. bends, branches, etc, and which do not constitute an
'obstruction' in terms of the definition referred to in (a)
M.2 Design Considerations
previously.
M.2.1 Inspection and servicing requirements are set out in
Section 20 of this specification. M.2.5 Careful consideration must be given by the designer to
the practical problems associated with the manufacture
M.2.2 Care, protection and standards of cleanliness prior to and fitting of suitably sized access panels on both small
commissioning are set out in the HVCA publication cross section rectangular ducts and the circular faces of
DW/TM2 "Guide to Good Practice, Internal Cleanliness round and flat oval ducts and the ductwork manufacturer
of New Ductwork Installations" and the guide states should be instructed accordingly.
"Where specific levels of cleanliness are required, duct-
work shall be cleaned after installation by a specialist M.2.6 Cleaning requirements for both new and existing ventila-
cleaning contractor". tion systems are set out in the HVCA publication TR/17,
"Guide to Good Practice, Cleanliness of Ventilation
M.2.3 It will be in the interests of the designer, both financially Systems". The guide establishes standards for testing,
and practically, to consider employing a specialist clean- cleaning and verification and provides greater detail for
ing contractor at the outset of a contract to internally the designer's consideration than the basic information
clean newly installed ductwork prior to hand-over. This included in this appendix. The guide also includes the
approach would realise the following benefits:- statement; "The precise location, size and type of access
i) The actual number of cleaning access panels could would be dependent on the type of ductwork cleaning,
be determined to suit the method of cleaning to be inspection and testing methods to be adopted".
adopted.
ii) As a result of the involvement of a specialist clean- NOTE! In the absence of any indication by the designer
ing contractor, clear directions could be given to the for cleaning requirements, only the access panels
ductwork contractor as to the size and location of for inspection and servicing set out in Section 20
cleaning access panels that are required to be fitted of this specification will be incorporated into a
during the manufacturing process. new ductwork system.
iii) A specialist cleaning operation prior to-
commissioning would enable the cleaning contrac- M.2.7 Special consideration must be given by the designer to
tor to verify the practical access requirements for the
the practical problems associated with gaining personnel
future cleaning operations associated with a regular
access to heavily congested ceiling areas and multi-lay-
maintenance programme.
ered ductwork systems. Such consideration would avoid
iv) A specialist cleaning operation prior to commission-
the possibility of access panels being incorporated into a
ing would allow the designer to omit from the spec-
ductwork system at the manufacturing stage that were
ification the DW/TM2 requirements for factory
sealing, protection, wipe downs and capping-off. later found to be inaccessible for either servicing or
cleaning activities.
M.2.4 In the absence, at the ductwork manufacturing stage, of
any access panel size and location input from a specialist M.3 Access to in-line equipment
cleaning contractor then the designer may consider that
the following minimum requirements should be incorpo- M.3.1 This appendix only covers access/inspection through the
rated into a new ductwork system: - ductwork body adjacent to an item of in-line equipment
a) An access panel, of specified size, should be fitted and not openings in the equipment itself.
upstream of any internal 'obstruction' i.e. splitters,
airtums, blades, pods, coils, filters, etc. The panel is Appendix M (Revised) June 2002
APPENDIX N – BIBLIOGRAPHY
Included in this Bibliography are technical publications which Research Reports
may be of interest to ductwork designers. fabricators and erec- RR01/95: Ventilation system hygiene — A review of
tors, and to those in the heating, ventilating, air conditioning published information on the occurrence and
industries generally. Enquiries should be made of the relevant effects of contamination
organisation, at the address quoted. Since its publication other RR02/95: Air-to-air heat recovery
addresses contained within DW/144 may have changed, and RR03/95: Influence of HVAC on smoke detectors
some publications may have been superseded.
HEATING AND VENTILATING NATIONAL ENGINEERING SPECIFICA-

CONTRACTORS’ ASSOCIATION TION LIMITED
34 Palace Court, London W2 4JG Telephone: Southgate Chambers, 37/39 Southgate Street,
0171-229 2488; Fax: 0171-727 9268. Winchester SO23 9EH
(Telephone: 01962 842058; Fax: 01962 868982)
Orders to HVCA Publications, Old Mansion
House, Eamont Bridge, Penrith. Cumbria CA10 2BX BUILDING SERVICES RESEARCH AND
(Telephone: 01768 864771 Fax: 01768 867138) INFORMATION ASSOCIATION
Email: hvcapublications@hvwelfare.co.uk
Old Bracknell Lane West, Bracknell, Berkshire

DW/144 Specification for sheet metal ductwork (low-,
RG12 4AH (Telephone: Bracknell (01344)
medium- and high-pressure) (1998)
426511; Fax: 01344 487575)
DW/143 A practical guide to ductwork leakage testing
(1983)
Application Guides
DW/151 Specification for plastics ductwork
AG.1/74 Designing Variable Volume Systems for Room
DW/171 Guide to good Practice for kitchen ventilation
Air Movement
systems
DW/191 Guide to good practice glass fibre ductwork AG.1/91 Commissioning of VAV Systems in Buildings.
DW/TM1 Acceptance scheme for new products — TN.6/94 Fire Dampers
Rectangular cross joint classification LB.65/94 Ventilation of Kitchens
DW/TM2 Guide to good practice — Internal cleanliness of
AG.3/89 The Commissioning of Air Systems in Buildings
new ductwork installations
DW/TM3 Guide to good practice for the design for the AH.2/92 Commissioning of Bems - A Code of Practice
Installation of fire and smoke dampers TN.24/71 Fire Dampers in Ventilating Ducts.
Other publications
JS1 H&V safety guide 5th edition HEATING, VENTILATING AND AIR
JS2 Tool box talks CONDITIONING MANUFACTURERS
JS5 Welding Safety booklet ASSOCIATION (HEVAC)
JS19 Safety facts booklet. Fact sheets 1-24 2nd Sterling House, 6 Furlong Road, Bourne End,
edition Bucks SL8 5DG (Telephone: 01628 531186 Fax:
JS21 COSHH manual volume 1 Advice on compli- 01628 810423 Email: info@feta.co.uk)
ance with the regulations
Publications
JS 21A COSHH manual volume 2 Assessment sheets
Air Diffusion Guide
JS23 Risk management manual
Guide to Air Handling Unit Leakage Testing
TR/3 Brazing and bronze welding of copper pipework
Guide to Good Practice: Air Handling Units
and sheet (1976)
Real Room Acoustic Test Procedure
TR5 Welding of carbon steel pipework (1980)
Specification for the Certification of Air Filters
TR6 Guide to Good Practice for Site Pressure Testing
of Pipework (1980) Method of Test for Water Rejection Performance of Louvres
TR17 Guide to good practice cleanliness of ventilation Subjected to Simulated Rainfall
systems. Test Procedure for Acoustic Louvres
Specification for Floor Grilles – Types, Performance and
CHARTERED INSTITUTION OF BUILDING Method of Test
SERVICES ENGINEERS Specification for the Determination of the Collection
Delta House, 222 Balham High Road; Efficiency of Sand Trap Louvres
London SW12 9BS (Telephone: 0181-675 5211 Domestic Mechanical Ventilation Systems with Heat
Fax: 0181-675 5449) Recovery
CIBSE Guide Fan Application Guide
Volume A Design Data Fan and Ductwork Installation Guide
Volume B Installation and Equipment Data Guide to Fan Noise and Vibration
Volume C Reference Data
Specification of Requirements for Natural Smoke and Heat
Commissioning Codes Exhaust Ventilators
These Codes cover the preliminary checks, setting to work Specification for Powered Smoke and Heat Exhaust
and regulation of various categories of plant. The Codes give Ventilators
a guide to design implications. Specification of Requirements for Smoke Curtains
Series A Air Distribution Systems
Design Guide of Smoke Ventilation for Single Storey
Series B Boiler Plant
Industrial Buildings Including those with Mezzanine Floors
Series C Automatic Control Systems
and High Racked Storage Warehouses – Issue 3
Series R Refrigerating Systems
Series W Water Distribution Systems Guidance for the Design of Smoke Ventilation Systems for
Covered and Underground Car Parks – Issue 1
Technical Memoranda Application of Smoke Control Equipment and Systems:
TM 4 Design Notes for the Middle East Guide to Good Practice – Issue 1
TM 8 Design Notes for Ductwork
TM 13 Minimising the Risk of Legionnaires Disease
95
BRITISH STANDARDS INSTITUTION SHEET METAL AND AIR CONDITIONING
Sales Department, 101 Pentonville Road, London CONTRACTORS’ NATIONAL
N1 9ND (Telephone: 0171-837 8801) ASSOCIATION INC. (SMACNA)
Headquarters:
BS 381C:1996 Colours (of ready-mixed paints) for specific
purposes 4201 Lafayette Center Drive
Ducts for building services
Chantilly
CP 413: 1973
Virginia 20151-1209
BS 476: Fire tests on building materials and structures
Part4: 1984 Non-combustibility test for materials Mailing Address
Part6: 1989 Fire propagation test for materials P.O. Box 221230
Chantilly
Part7: 1993 Surface spread of flame tests for materials
Virginia 20153-1230
Part 20: 1987 Fire resistance of elements of con-
struction Telephone (703) 803-2980
Part 21:1987 Fire resistance of loadbearing elements Fax (703) 803-3732
of construction
Part 22:1987 Fire resistance of non-loadbearing
Accepted Industry Practice for Industrial Duct Construction
elements of construction
(1975)
Part 23:1987 Contribution of components to the fire
resistance of a structure Architectural Sheet Metal Manual (1993)
Contractors Guide for Modification to Construction Contracts
Part 24:1987 Fire resistance of ventilation ducts
(1993)
BS 5588
Part 9:1980 Fire Precautions in the design and con- Ducted Electric Heat Guide for Air Handling Systems (1994)
struction of buildings Energy Conservation Guidelines (1984)
BS 729:1971 Hot dip galvanized coatings for iron and Energy Recovery Equipment & Systems (1991)
steel articles Fibrous Glass Duct Construction Standards (1992)
BS 1449: Steel plate, sheet and strip Fire, Smoke & Radiation Damper Install. Guide for HVAC
Part 1:1991 Carbon steel plate, sheet and strip Systems (1992)
Part 2:1983 Stainless steel plate, sheet and strip. Guide to Steel Stack (1995)
and HVAC Air Duct Leakage Test Manual (1985)
BS.EN10149-2: 1996 HVAC Commissioning Manual (1994)

HVAC Duct Construction Standards-Metal & Flexible (1995)
BS.EN 10149-3: 1996
Addendum No. 1 (Nov 1997)
BS.EN 10131: 1992
HVAC Duct Systems Inspection Guide (1989)
BS.EN485 Wrought aluminium and aluminium alloys
Parts l-4 for general engineering purposes – plate, HVAC Systems-Application (1986)
BS.EN515 1993 sheet and strip. HVAC Systems-Duct Design (1990)
BS.EN573 HVAC Systems-Testing, Adjusting & Balancing (1993)
Parts l-4 Indoor Air Quality Manual (1993)
BS 1474:1972 Wrought aluminium and aluminium alloys Kitchen Equipment Fabrication Guidelines (1990)
and bars, tubes and sections Managers’ Guide for Welding (1993)
BS.EN755 Rectangular Industrial Duct Construction Standards (1980)
Parts 3-6 Round Industrial Duct Construction Standards (1977)
BS.EN22063: Sprayed metal coatings Seismic Restraint Manual (1991) (w/ Appendix E, 1993)
1994 Protection of iron and steel by aluminium SMACNA Master Index of Technical Publications (1995)
and zinc against atmospheric corrosion
Thermoplastic Duct (PVC) Construction Manual (1994)
Protection of iron and steel against
corrosion and oxidation at elevated DEPARTMENT OF THE ENVIRONMENT
temperatures
(Publications Centre)
BS.EN10142: Continuously hot-dip zinc coated mild
H.M. Stationery Office, 51 Nine Elms Lane,
1991 steel strip and sheet for cold forming -
technical delivery conditions
London SW8 5DR
BS.EN10143: Continuously hot-dip zinc coated and M & E No.1 1972 Electrical installations in buildings (New
1991 ironzinc alloy coated steel sheet and strip - Edition)
tolerances on dimensions and shade M & E No.3 1988 Heating, hot and cold water, steam and
BS 3533: 1981 Glossary of terms relating to thermal gas installations for buildings
insulation
M & E No.4 1970 Central heating and hot and cold water
BS.EN.ISO: 1479 Self-tapping screws and metallic drive screws
installations for dwellings
BS.EN.ISO: 7049:
M & E No.100 1971 Mechanical ventilation for buildings
1994
BS 4800:1989 Paint colours for building purposes BRITISH STEEL PLC
BS 4848: Hot rolled structural steel sections Market Communications Dept
Part4: 1972 Equal and unequal angles British Steel PLC
BS 5422:1990 Specification for the use of thermal insula- Strip Products
ting materials P.O. Box 10 Newport
BS 5720: 1979 Code of practice for mechanical ventilating South Wales NP9 0XN
and air conditioning in buildings (Telephone 01633 290022)
BS 5970: 1992 Code of practice for thermal insulation of (Fax 01633 464087)
pipework Publication: Edge protection by zinc
96
ASSOCIATION FOR SPECIALIST FIRE HEALTH AND SAFETY EXECUTIVE
PROTECTION Rose Court
Association House 2 Southwark Bridge
235 Ash Road London SE1 9HS
Aldershot Telephone 0171-717 6000
Hampshire GU12 4DD
Telephone 01252 21322
Fax 01252 333901
Publications.
Fire Rated and Smoke Outlet Ductwork: An
Industry Guide to Design and Installation.
APPENDIX P – CONVERSION TABLES
Sheet thicknesses
Galvanized steel * Aluminium
Standard Birmingham Standard Standard

thickness Gauge thickness Wire Gauge
inch mm BG inch inch mm swg inch
.0197 0.5 26 .0196 26 .018
.0236 0.6 24 .0248 .0197 0.5
.0276 0.7 24 .022
.0315 0.8 22 .0312 .0236 0.6
.0354 0.9 .0276 0.7 22 .028
.0394 1.0 20 .0394 .0315 0.8
.0472 1.2 .0354 0.9 20 .036
18 .0495 .0394 1.0
.0630 1.6 16 .0625 .0472 1.2 18 .048
.0787 2.0 14 .0785 .0630 1.6 16 .064
.0984 2.5 12 .0991 .0787 2.0 14 .080
.0984 2.5
12 .104
0.5 mm is a standard thickness for galvanized
sheet only .1181 3.0
10 .128
2.5 mm is a standard thickness for hot-rolled
sheet only
* See Appendix K (Section K.3) which contains

information on gauge and sheet width/length
tolerances
97
Some miscellaneous conversion factors
To convert Multiply by To convert Multiply by

Length
Inches to millimetres 25.40 Millimetres to inches 0.03937
Feet to metres 0.3048 Metres to feet 3.281
Area
Square inches to square millimetres 645.2 Square millimetres to square inches 0.00155
Square feet to square metres 0.0929 Square metres to square feet 10.764
Volume
Cubic feet to cubic metres 0.02832 Cubic metres to cubic feet 35.315
Cubic feet to litres 28.31 Litres to cubic feet 0.0353
Gallons (UK) to litres 4.546 Litres to gallons (UK) 0.22
Mass
Ounces to grams 28.35 Grams to ounces 0.03527

Pounds to kilograms 0.4536 Kilograms to pounds 2.205
Tons to tonnes 1.016 Tonnes to tons 0.9842
Volume flow
Cubic feet per minute to cubic Cubic metres per second to cubic
metres per second 0.000472 feet per minute 2119
Cubic feet per minute to litres Litres per second to cubic feet
per second 0.4719 per minute 2.119
Motion
Feet per minute to metres per second 0.00508 Metres per second to feet per minute 197
Pressure
Inches water gauge to millibars 2.491
Inches water gauge to pascals (Pa) 249.1
1 Pa = 1 Newton per square metre = 10–2 millibars
Standard dimensions of steel

and aluminium sheet
Steel
(mild and galvanized)
Metric Equivalent
mm ft/in
2000 × 1000 6' 6 3 / 4 " × 3' 3 3 / 8 "
2500 × 1250 8' 2 7 / 16 " × 4' 1 1 / 4 "
3000 × 1350 9' 10 1 / 8 " × 4' 5 1 / 8 "
3000 × 1500 9' 10 1 / 8 " × 4' 11 1 / 16 "
Weight of galvanized steel sheet
Weight per
Thickness square metre
mm kg
0.5 3.9213
Aluminium 0.6 4.7056
(commercially pure and alloy) 0.7 5.4898
0.8 6.2741
Metric Equivalent 0.9 7.0584
1.0 7.8426
mm ft/in 1.2 9.4111
2000 × 1000 6 ' 6 3/ 4 " × 3 ' 3 3/8 " 1.6 12.5481
2500 × 1250 8' 2 7/16 " × 4' 11/4 " 2.0 15.6852
3750 × 1250 12' 3 5/ 8 " × 4' 11/ 4 " 2.5 19.6064
98
Details of how to obtain
further copies of this
guide and other
publications are
available from:
HVCA Publications
Old Mansion House
Eamont Bridge
Penrith
Cumbria
CA10 2BX
Tel: 01768 864771
Fax: 01768 867138
e-mail hvcapublications@hvwelfare.co.uk
Heating and Ventilating Contractors’ Association

Esca House 34 Palace Court London W2 4JG
Tel: 0171-229 2488 Fax: 0171-727 9268

HVCA - DW144 - Spec For Sheet Metal Ductwork

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HVCA - DW144 - Spec For Sheet Metal Ductwork

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Specification for

Low, medium and high

Copyright © 1998 by the

All rights reserved

Further copies of this publication are available from:

or more than a decade-and-a-half, the DW/142 Specification for Sheet Metal

F Ductwork published by the Heating and Ventilating Contractors’ Association

L must be prepared continually to innovate in

• the omission of high-pressure Class D (in order

• the highlighting of information to be provided

• the removal of standard sizes of rectangular

• the acceptance of proprietary flanges certificated

• the consolidation into the document of coverage

• the addition of a note on linings, along with their

• the consolidated graphical representation of significantly in the achievement of this objective.

The HVCA wishes to record its sincere thanks to the following

Edgar Poppleton (chairman)

Ductwork Group Secretary:

DW/143 A Practical Guide to Ductwork Leakage Testing

Copies of the above publications are available from:

Previous Sheet Metal Ductwork Specifications

Page 16.4 Fastenings 35

5. Application 13 21. Regulating Dampers 48

Part Four - Circular Ducts 64-75 Horizontal ducts

Part Seven - General

Part Three - Rectangular Ducts

(3) Manufacturing techniques are continually subject to change and

Plant rooms and risers Class C

2 STANDARDS 4.4 Internal thermal/acoustic lining

5 APPLICATION 6.3 Leakage at various pressures; and other

Where p is the differential, pressure in pascals.

in DW/TM1 “Acceptance scheme for new prod-

10.3.2 Welded seams 10.5.1 External stiffeners

Group, have produced an Addendum No.1 fabrication.

10.7.5 Welding of sheet The maximum length of turning vane between

Maximum duct size

PS 3000 2000 1600 1250 1000 800

Notes (applicable to Tables 2 to 4)

Maximum duct size

PS 3000 1600 1250 1000 800

PS 3000 1250 1250 625

Constructional Requirements – Rectangular Ducts

Maximum duct size

J2/S2 PS/SS 3000 1250 800

Notes on page 18 also apply to Tables 3 and 4

Fig. 1 Grooved seam Fig. 5 Returned standing seam (internal or

Fig. 2 Grooved corner seam Fig. 6 Capped standing seam (internal or

Fig. 9 Illustrations of panel stiffening

Pleating (may also

Beading (may also

Examples of Cross sections

Fig. 10 Rolled steel angle- Duct ends turned up 8 mm

40 x 4 8 mm A turn up as illustrated is NOT

Fig. 11 Examples of typical rollformed sheet metal profiles

Sealant, clamps/cleats and fixings omitted for clarity

Alternative sealant locations Fastening

Fig. 15 Angle reinforced (Ducts with

Corners can be mitred

Fig. 16 Back to back stiffeners (Ducts with Locate stiffener back

Stiffeners shown in Figs.

Fig. 17 Full girth welded stiffeners Locate stiffener back

Section H Thickness Rating

Illustrations show rolled steel angle